Motor arrived

The Kostov K9HV arrived yesterday from Bulgaria. It is a really neat little motor and I am amazed it will be able to accelerate the A2 0-100 in 10 seconds and give it a top speed of 130 km/h. Well, we'll see!

First spin

I connected it to 12V and gave it a first spin and it works allright. I also connected the motor-transmission adapter to it.

When I mounted the flywheel to the adapter I noticed a substantial unbalance. So severe that I had to shut it down after just a few seconds. After some investigation it turns out the flywheel is unbalanced!

The unbalanced flywheel. Note the big piece of material missing in the lower left!

I thought I was smart to get exactly the flywheel that is used on the engine that fits the transmission that I'm using. But that engine is a three cynlinder diesel engine which, because it has only three cylinders, is unbalanced. To counteract the imbalance of the engine VAG made the flywheel equally unbalanced the other way. That means the flywheel will only work with those three cylinder engines and not my perfectly balanced little Kostov motor :(
So the solution is to use another flywheel. I hope the existing flywheel from the four cylinder petrol engine in the car will work. The only difference I know of is that the clutch is smaller on the petrol engine so maybe the diesel clutch will not fit.

Finally something happens!

I haven't been doing much on the project for quite a while, I must admit. I have been driving around in my little A2 which is a quite nice car even with a gas engine in it ;)

But now things are starting to move again!

I have shopped around for parts and they are slowly arriving at my garage.
68 CALB100FI batteries have been ordered from ev-power.eu. The are due to get here in the end of June.
A Brusa NLG-513 charger has arrived from Brusa in Switzerland. The Brusa is the best charger around, I think, since you can configure it pretty much anyway you like. Brusa actually had a sale on them so I got it for half price! :)

The Brusa charger with cables 

After some discussions with Joost at Rebbl in the Netherlands I decided to order a Meanwell SP-750 AC/DC converter from Elfa to use as a DC/DC converter. Sounds nuts, but it turns out the Meanwell can take AC as well as DC current as input. Up to 370VDC input and it produces a nice 13.5VDC which will charge the little 12V battery a bit. I am taking a chance that it's power, 750W will be enough. The DC converter is CE marked and has nice EMC certificates.

A Kilovac 500A, 500V contactor is on its way from Farnell in the UK via its Swedish reseller Microkit.
Today a used transmission from a Audi A2 1.4TDI arrived. as did a clutch from the same car and a flywheel from a VW Polo. I have to change the transmission too, remember? Just like I changed the brakes just because of stupid Swedish regulation. Nevertheless It is good to have it here and being able to measure it without ripping the car apart.

Flywheel and clutch

The flywheel is from a Polo with the same engine as the A2 (1.4 TDI with motor code AMF) so I hope it will fit the transmission. Look at the picture below, it is tight!

I am thinking of maybe buying a VW New Bettle motor adapter from Rebbl and I have sent them some measurements of the transmission and flywheel to check if it will fit.
More stuff I have to decide upon now are AH meter to measure battery charge, current shunt, volt meter, a 500A fuse, shielded battery cable, battery connectors for connecting the CALB cells to eachother and a lot more...
I have pretty much decided to go for the Kostov K9HV motor and the Evnetics Soliton Jr controller, but they are not ordered yet.