Archive for December, 2008

GT 40 Reference Photos

Restoring and Building | Posted by admin December 31st, 2008

Following are photos of the Ford GT40 that this car is modeled after. The Valkyrie used the 1960’s GT as it’s model, the following are some shots of what I believe is a 2003 Ford GT40. Ford made a lot of improvements especially in the way of comfort. As I complete my EV-GT I plan on modeling it as much as I can on this model.

EAA Meeting and Park Vista Car Show

Research | Posted by admin December 13th, 2008

One of the best ways to get good information is visiting a local chapter of the Electric Auto Association. I am real lucky that there is a real active group right in my back yard. Today I spent the day attending a meeting in the morning the joining some of the guys who already had running electric conversions at a local car show.

(I didn’t take enough notes at the show, so if any of the guys from the Florida EAA can drop me a note with more info on these cars, I will gladly update this page.)

This 240SX had its maiden voyage to the show.  Done by Charlie at Vintage Voltage.

This Porsche is actually a high school project.  A really nice conversion that has also been a race car.

Shawn’s really cool electric motorcycle.

This Electric truck was done by Al Lococo in Winter Haven, FL.  He has a nice website with lots of details.  Click here to see his site.

Al used the same method that I was going to do to mate the Warp 9 to the transmission.  He had a problem with the system when one of the springs failed.  After talking to a couple of other guys at the show I think I am going to rethink how this is done and eliminate the clutch plate.

These cars were not electrics, but were very cool cars.  I liked the clean electronic dashboard on this hotrod.

I was lucky enough to find a new Ford GT40 at the show.  Unfortunately the guy was just about to leave when I got there so I didn’t get a chance to really look over the details in the car.  This was a shame.  It might have given me some good ideas on how to finish out my car.

Side windows

Restoring and Building | Posted by admin December 4th, 2008

The side windows on the Vallyrie kit seem to be the poorest thought out part of the kit design. The plans call for using a 1965 Ford Mustang corner window and 1965 Ford LTD 4DR hardtop side glass. When I bought my car the previous builder had already installed the Mustang corner glass but the LTD glass was missing as was the lifts and regulators. After a lot of searching, Ford LTD glass was found. After receiving the glass and test placing it, a real problem raised it’s head. The LTD glass was going to hit the door locks. It also was not going to match the curve of the Mustang guide rail. There is also going to be an issue placing the door locking lever. This is going to take some thinking.

The problem is the previous owner installed a lot of thing wrong. (Not the first time I have found this.) The Mustang windows were mounted to the door not the inner panel as instructed in the manual. The latch and handle were also wrong. These were all removed and work has begun on doing it right.

The curve is actually wrong but with softer rubber it should work. I ordered new rubber. I have also done some modification to change the curve slightly so the windows will closer match the right curve.

The regulators and tracks arrived and like almost all these old parts they were rusty. It was just surface rust so into a chemical bath they went.

The old 1968 manual makes it all look easy but it misses a lot of details and the photos are poor. As I was mounting the parts on the inside door pannel I realized I was going to need to use bolts as posts to hold a lot of the parts just off the pannel. I also needed to be able to adjust them to get the glass to line up in the car. I had to do a lot of back and forth adjusting to get it right. I also had to drill a couple of holes before I found the right spot. Luckely is pretty easy to fill in old holes with some fiberglass epoxy and glass powder.

Connecting the Motor

Restoring and Building | Posted by admin December 3rd, 2008

Connecting the electric motor to the Corvair transmission has required a lot of thought. My first reaction to the fly wheel and clutch plates when we took off the motor was that they added a lot of weight and were they needed in an EV. If you aren’t aware, any weight that is spinning in a vehicle does a lot to reduce acceleration. Eliminating a pound of spinning weight is like removing 3 pounds of normal weight so having this big flywheel and clutch in the car was a lot of weight that could be removed. Since an electric motor comes to a complete stop when the power is removed, you don’t have to disconnect it like you do an gas engine which continues to spin even when it idles. After talking to some of the guys at the local EAA club I decided that I was going to eliminate the clutch all together. The reality is that my math shows that almost 90% of my normal driving can be done entirely in 2nd gear. Only on the highway would I need to shift to 3rd and only if I wanted to really fly would I go to fourth.

The Warp 9 motor has a keyed 1.125″ shaft that needs to be connected to the shaft of the transmission. Looking at the clutch, I want to keep the springed system that it uses for dampening the shock. I designed an adapter that would allow me to bolt the inner part of the clutch plate to an adapter that would slip on the keyed shaft of the Warp 9 motor. The motor also has a threaded hole on the end that will allow me to bolt this adapter in place so it doesn’t slip off. I also wanted to eliminate the bell housing since doing so allowed me to drop 4 more batteries in, 2 on each side of the transmission.

Sketch of how it should go together

Sketch of how it should go together

Cross section sketch of the adapter

Cross section sketch of the adapter

Motor mount and clutch plate adapter

Motor mount and clutch plate adapter

clutch plate adapter - motor end

clutch plate adapter - motor end

The clutch plate adapter will allow the clutch plate with the removed friction plates to mount to the electric motor shaft.

This is a photo of the shaft with the clutch plate slid onto it.

This is the clutch plate with the unneeded material removed.

The Interior- Seats

Restoring and Building | Posted by admin December 2nd, 2008

Today I went and picked up my wife at the airport. She was returning from visiting my father in law in South America. When she left she took with her the patterns for the car seats she and I had worked out. While she was there she and my father in law took the patterns to some local shops and had the seat covers made. I was excited to see the final product. Custom fit and professional. They need to be stretched and tacked onto the seat foam, but I had to see how they were going to look in the car. Special thanks to my father in law for his help.