Chevy Volt and Electric 3 series BMW (Ev-36/46)

Well here is the motor mount. It attaches to the 2 side bolts on the motor and 2 of the front bolts. I'm attaching it to the crossmember using using 2 existing holes. I used 2 rubber transmission mounts instead of motor mounts as they are smaller and this motor is lighter than the gas engine. I also didn't go with the ICE engine motor mounts and locations as I wanted to leave room on the side of the motor for another battery. I think it turned out well. Location is good being Dead center and level. Oh wire arrived today. Looks nice and beefy (4/0) and is quite flexible. I need to select and find a place to buy the fuse, circuit breaker and shunt. The motor mount I think will work out great. I am a mechanical engineer and use to design weldments as a job years ago. Did not do any analysis on this structure, other than rough numbers for the force that'll be applied at the mount points, but it should be plenty strong. And small is light and more room for the batteries. Oh

I was looking around and found some tinned lugs with the right bolt hole in them for a reasonable price. Think I'll just order them. I have my motor mount bracket just about done. Painted it last night. will have to get some pictures and post it. Went a little different way than what I have seen most do.

I ordered the main wiring. After some reading I realized that 4/0 wiring is probably overkill and should buy 2/0. Cost difference would probably be about $100. Then I thought to myself.....if this were a gas car and I could get a few HP for an extra couple of bucks would I do it? Sure I would. Ordered 4/0 wire. I also ordered a hammer crimper. I have a hydrolic press so I'm thinking I can just put it in the press instead of whacking at it with a hammer. I haven't ordered any lugs. I'm wondering if I can make some out of some copper tube. Prices seem to be a ripoff and I didn't see any with the through hole I needed. I'll give it a go after the wire arrives. Manged to get a battery in my fuel tank location battery rack. I was able to test the clearances in the front and rear location. Looks like it'll work out great. Getting it up there with the batteries in it is going to be a trick but I'll worry about that when I get that far. I'm sure it can be done.

Finally had a saturday where I wasn't travelling, there wasn't another car repair I had to do, the kids didn't have a scoccer game etc. so I got some work done on the EV. I'd really like to get it so it'll move under it's own power so I can move it out of the garage during the week. Started on the gas tank location battery rack. Made some good progress so far. Here's a pict in the middle of construction.

Installed the Hall effect sensor Pedal. I keep wanting to call it a GAS pedal but obviously that's not right. My boy keeps correcting me with "Accelerator" pedal. Pic attached of the pedal installed. Have also connected the wire. I reused the firewall fitting/gromet that the cable had used. Just drilled it out a bit larger for a nice snug fit on the wire. Makes for a nice clean installation. I also finished the high pressure and low pressure brake fluid lines. The 92-95 BMW's had low pressure brake fluid lines going from the fluid reservior to the ABS unit (see the picture). So I did a remote mount of the BMW fluid tank to the Mustang master cyl and ran new lines to the ABS. Doing some research I found that EPDM style rubber hoses are recommended for use with brake fluid. Looking around locally I found that hose made for farm fertilizer etc sprayers are made of the same thing. So I got some at tractor supply. So far it looks like it will work good. The metal for mak

Forgot to mention that on the MR2 pump I realized that the reservior could be rotated so that the return fitting could point another direction. However the bump on the inside of the reservior hits on some of the parts of the pump. I took off the plastic reservior and took a picture. See attached. So you get a better idea of what I'm talking about. So to orient the outlet at a very different angle it may require removing the reservior turning to the direction and refitting. sadly there are a few angles where it just can not be placed but that's not to big of a deal. Also shown is the braided steel hose and fittings I used to make the custom AN style High pressure lines. Like what is common on race cars. It is easy enough to do. In my set up I have one line going from the PS pump to the hydro boost and one from the hydro boost to the P/S Rack. I need to finish the return lines then I could give the hydrolics a try. Adapter fittings purchased from pegusus parts www.pegasusautorac

Ok things are busy and I'm not in a big hurry to finish as I enjoy having a project. So after some family vacations and more repairs on my ICE cars I did get back to the electric car. Update: The Batteries I decided I wanted to use were Deka 9A31. Nearest dealer for them was 90 miles from my house in NC (I live in the middle of nowhere). I called them to see if I could come by and pick some up and they referred me to the dealer that "covered" my area. Well the dealer that "covered my area" was in TN and I'm in VA. So I don't see how that worked. But after some discussion they decided to let me pick them up at the closer site in NC. Thursday I took my SUV and trailer down. I had to pick up the wife and kids at the Charlotte airport that direction anyway. Well on the way down my trusty trailer, that I've had for years and towed thousands of miles, decided to start shedding parts. After being signaled by another motorist I found I'd lost