April 9th, 2012
Ok, so I got the cooling working – had to reseat the pump, as the o-ring has come loose somehow.
So I still have problems with the controller. However, no way to know what is up without the RS232 hookup. Well, I spent about 5 hours on Sunday getting the comm to work. Sort of. First off, the wires out of the controller are backwards. Secondly, the controller itself keeps getting confused.
Example: turn on the controller, listen to the RS232, status is ok. Spin the motor a bit, and the motor thinks it is in overtemp. Spin it again, and the overtemp goes away.
Example: motor speed is a 16-bit value. This value NEVER goes below 762.
Example: voltage is a 16-bit value. This value ranges from 700 to 20,000. Never stable.
Next stop is CANBus to see if that is any better.
So far, this controller is rating a C (or maybe C-). Or for those of the digital persuasion: 4/10.
Oh – and still haven’t gotten regen to work – no clue why not.
April 1st, 2012
So I was right – it was the cracked/cheap/broken connectors to the motor controller. I replaced all of the connectors on the controller, and the motor now works VERY well. I really can’t use first gear anymore.
However, I discovered that I mounted the water pump in a bad position. According to some sites, I’m not supposed to put the inlet of the pump in a vertical position. Will keep you appraised of that.
Meanwhile, the new motor is just awesome. Once I get more comfortable with it, I just might burn rubber. O_O
March 23rd, 2012
I took the car for a brief drive up and down the block. Really sad performance – I need to find out what is wrong, as this is not how it should perform.
Will keep you posted.
March 17th, 2012
Ok, so the cooling system is all in place now – no leaks. I’ve got the pump hooked up to run whenever the key is on. Makes a small gurgle noise, so there is still some air in the system.
Hints: when installing new hoses, stretch the new hose where it will go over the barbs – makes life a LOT easier for the installer. Also, make sure the fittings are snug – otherwise, while the hose might be water-tight, the fitting could leak.
I was hoping to bring the car off the jackstands this weekend, but with the rain coming through, it is not very likely. Really don’t want to mix rain and electrical parts – especially since I haven’t re-installed the rear trunk lid.
I’ll post a picture of the radiators later.
March 9th, 2012
Ok, the adaptor is complete, and ready to install. We’ve made a few attempts to put it in, but had a problem with the spacing around the clutch. This has been resolved by allowing the pressure plate to move back 0.2″. During the wait, I’ve rewired the relays, added in a pump and resevoir, and a third brake light. Hope to have the motor and transmission installed on Sunday.
The brake light is a strip of weatherproof side-facing LEDs from www.superbrightleds.com. The wires are hidden behind the chrome.
Since both the motor and the controller use liquid cooling, I had to add in a pump and reservoir. I’ll be running coolant lines from the pump to the controller to the motor to the radiators and back.
The new motor is heavy – 98kg! (216lb). So we have to use this hoist to get the motor and transmission into the car.
Motor hanging on a chain
The new motor is significantly larger than the old one. The gap between the new motor and the battery rack is about 6mm (1/4″).
January 25th, 2012
I was told 3 weeks for a new adaptor, and its only been 2 weeks. I must be getting impatient. Meantime, I’ve updated my wiring diagram, and will start the rewiring this weekend (subject to the usual interruptions).
I’m also trying to find some software so I can talk to the motor controller, but that’s a very difficult proposition.
December 11th, 2011
As a public service, I hereby proclaim:
DO NOT USE PERMANENT LOCTITE!
At some point in the future, you will need to dismantle your machine, and using permanent loctite will make this a very painful experience.
Use blue loctite instead.
(This was discovered as we were trying to dismantle the old motor adaptor).
November 24th, 2011
Well, I’m going to use a different machinist to create the motor adaptor. It’s going to be a big project, as the current motor is only 9″ in diameter and the new motor is about 13.5″ in diameter. So we have to move the rear battery pack up 1.5″, and create a new motor mount for the motor – so it will be a squeeze fitting it in.
Plus, we have to mill a brand new motor adaptor – this will mate the motor to the transmission. This adaptor has to be precisely a certain length in order for the clutch to work properly.
Work starts on monday. Will keep you posted on the progress.
October 31st, 2011
Well, my mechanic informed me that the shops that would do computer-controlled CNC are backed up for 2 to 4 months. So he’s going to do it the old fashioned way – milling machines and measuring. This is, of course, for the new motor adaptor for the new motor. Hey – with luck I’ll be driving the new motor by New Years. 🙂
September 30th, 2011
When the heat strikes I do to. Once the temp goes above 90, I have difficult leaving the house. This is partly due to living in Santa Cruz for so many years, and personal preference.
Anyways, I got the front wheel bearings tightened up today – they were wobbling a bit and I didn’t know why. After the mechanic stopped laughing at me, it took all of 20 minutes to do. I’m really hoping to start replacing the battery interconnects soon – I want them done before the new motor mount shows up (is taking a while to get a 3d model built up – more money would speed things for sure).
September 18th, 2011
As promised, here is the diagram with relays so you, too, can spin your GLEC motor.
Thanks for all the help – I hope this helps others as well.
September 7th, 2011
Wow. Took a while, but with a new job, spare time is hard to come by. At least I won’t be travelling for business (yay!).
Turns out that I had to enable the forward pin by applying +12v. The contactor line-out is also a ground source (so I had to have the contactor supply +12 to the line). Interesting method, not what I’m used to, so it was a surprise.
I’m going to update the diagrams and will post them, just in case someone wants them.
August 10th, 2011
I just got the car back from the mechanic. I had a problem with intermittent electrical issues (the 12v system, not the electric drive). For some reason, brake lights and turn signals were getting confused and not working. Turns out it was a the ground connection for the main wiring harness being rusty and not connecting properly.
My advice to you: convert the latest car you can.
A coworker’s advice: convert the largest car you can (she has a Kewet – tiny little thing). 🙂
July 28th, 2011
There are times when it is faster *and* cheaper to buy parts. Good examples are the motor, controller and stuff like that. Another example is battery interconnects. I had earlier posted that I need to have flexible battery interconnects, and that I was going to build them. Well, my mechanical skills are not so good, and the resulting interconnects are not very good.
So, I ended up buying most of them. From Australia. I have trouble believing that you cannot find these parts in North America….but I can’t find them here.
Good people at Evworks, I’ve bought from them before.
July 19th, 2011
Wow. I was going through the email that my friend in Shenzen was forward to me with some translation, and I FINALLY realized that I could also translate using Google. Well. Color me surprised. Yes, it was literally translated properly, but no, it wasn’t correctly translated. So, I’m trying to use Google Translate to do both english and chinese to the factory to make sure I’ve got it all correct with the controller.
For those following the saga at home, the 16-pin connector has a bunch of extra lines out. Those lines out (9-15) are options that can be programmed at the factory – meaning they do nothing for me. Now I just need to figure out how the potbox connects and whether I really need -12 and +12 or just +12 and ground. Details, details. 🙂
July 4th, 2011
Well, remember the nice solid copper battery interconnects I hand-made? And how some people said I needed to use braided cable? Well, after doing Yet More Research, they were right. The problem is that batteries move – all the time – even if you have them strapped. Mine aren’t strapped. So if batteries move, and the interconnects don’t, the batteries eventually get damaged.
So, in an effort to build some new ones, I tried two techniques: wrapping copper plate around the cable, and crimping copper pipe to the cable. As you can see from picture, the pipe does a lot better job. The pipe crimps nicely to the cable, and doesn’t leave much sticking up (unlike the plate).
So – only 106 more connectors to build.
Copper plate on left side, copper pipe on right side
June 19th, 2011
My wife pointed out that the brake lights are very dim on the 914, and I had to agree. Since I’m using LED light bulbs, this shouldn’t be happening. It’s odd, though, the bulbs have between 11 and 15 LEDs but only the center LED is on. I checked the voltage, and it seems ok (13.2 volts), so it must be a current limitation somewhere in the system.
Apparently, the 914s have a weakness in their electrical system at the fuse box inside the main cabin. The wires get old and break, or the connectors lose their grip, or the wires get crushed by the fuse box and the insulation starts to go. Or all the above. Sparky is going back to the shop to see about fixing this very, very soon.
June 11th, 2011
I finally got tired of the rain pouring through the roof (even with the targa top on) and got Sean to replace all the rubber seals in the roof. Naturally, he had to take the seats out to do this, as it requires clambering about inside the small cabin. Of course, when he did this, he checked for rust (this is something you should always do with an older car, especially one without rust protection). Of course, he found rust.
Of course, he fixed it. AND added in a frame stiffener (914s are a bit weak along the cabin frame). VERY nice work.
Rust under the driver seat.
Frame stiffener and insulation.
More padding/insulation. Notice - no rust!
Cabin re-carpeted. No sign of Sean's work.
New rubber seals - apparently a major pain to do.
May 30th, 2011
I finally got some spare time and opened up the controller to see what I could see.
I have a clearer understanding of what most of the lines do – but still do not know where to hook up the accelerator pedal lines. There are 6 lines called “Function” that lead to KB5, KB6, KB7, KB8 and two unmarked inputs on the controller. Not much help there.
I also have a rough idea about the serial lines – three lines that are labeled “gorge line transmit, receive and place” which are hooked to T2OUT, R2IN and one unlabeled wire.
Front of the Controller
Wires from Front to Main Board
Wires from Front to Main Board
Rear of Controller
May 26th, 2011
Sorry about the delays – had a week-long face-to-face meeting, compleate with a BBQ at my house and a dinner at a local restaurant. Busy busy busy. I really hope to have time this weekend for reviewing the motor.