Integration test no 3 - succeeded!

I made two integration tests today and tried to mount the motor to the transmission.
After my frind Ola had machined off a centimeter of material from the flywheel it was balanced enough to test. I have been thinking of getting a special tool for centering the clutch plate to the flywheel bu now I just used a vernier caliper to measure the distance between the clutch plate and the holes in the flywheel and centering it manually. That turned out to be good enough. The garage hoist was a bless to use for navigating the 55 kg heavy motor/adapter/flywheel/clutch assembly.

Mounting the motor to the transmission

 

It turned out that the fit is so tight I could not get the motor and transmisstion together. Maybe the flywheel for the VW New Beetle, for which the adapter is originally made, has a smaller flywheel.
So, test number two failed as well.
I then removed the gear ring on the flywheel to make it smaller and shaved off a small indent on the inside of the transmission that seemed to be in the way.

After removing the gear ring from the flywheel

I used a simple propane burner that I normally use for an (other) outdoor stove to heat the gear ring and then a hammer and chisel to beat it off.

The indent before and after shaving with a angle grinder

Without the gear ring and indent I managed to push the motor and transmission together! Horray!
After reading several electric conversion blogs I now know that if you convert at car to electric you have to make a video with the first test run of the motor and transmission together ;) So, here is mine:

Motor-transmission adapter

The motor to transmission adapter arrived today from Rebbl in the Netherlands. It is manufactured by Rebirth Auto in th US for VW New Beetle. It turns out it fits perfectly on the Audi A2 1.4 TDI transmission. Apart from the M12 and M10 bolts it needs two guide pins to find the right position so I have to get those.

Tha adapter on the transmission

Also, the VW Polo flywheel fits nicely onto the adapter.

However, the bolts that I bought from a VAG shop for the flywheel didnt fit. They are thread M10x1 and they can be threaded down half a turn but then they get stuck. I also tried a normal M10 (M10x1,5) but it didn't fit either. I guess it could be a UNC thread that is used in the US so I will ask Rebbl and Rebirth Auto about it.

Different threads?

Or, I realize now when looking at thread tables that it could be a M10x1,25. Will try to find one tomorrow and test.

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.