Cutting Excess Metal Off Left Motor Mount

Bill found another person to help cut away the marked excess metal off of our left motor mount using a plasma cutter. The metal could have also been cut using our cut off wheel (our third cut off wheel purchased from Harbor Freight).

As you can imagine, we cut away any excess metal because metal adds weight. We want Sparky as light as possible for better battery operation thus additional miles traveled per charge.

We are trying to utilize the excess metal for future endeavors. The left and right pieces may be used for motor torque mounts. The upper piece may be used as a cooling plate.

Vacuum Pump Enclosure

We know the vacuum pump will be one of the loudest, if not the loudest, piece of equipment on Sparky. So we decided to build a box for it out of wood and line the box with the sound dampening carpet. Hopefully it will dampen the noise from the vacuum pump. The question remains... where to put it?

Left Motor Mount

We decided to bolt the motor mount plate to the original motor mounts that held the engine up. In order to do this, and to cut down on weight, we chopped about a 7" bar off of the original motor mount.

We took some measurements once the motor was level and drilled holes into the upper portion of the motor mount plate. Then we drilled coinciding holes into the original motor mount as well as cut off the excess metal end that we wouldn't use. Three bolts, a spacer nut between the plate and motor mount and three more washers, lock washers, and nuts and we were done for the day.

Motor Installation

We attempted the first installation of the motor into the engine bay. We knew the axle would get in the way of the transmission adapter plate, so we made the cut as close as possible to the transmission bell housing. Unfortunately, we didn't make the cut close enough. The transmission adapter plate was interfering with the axle into the transmission. Another mark, cut, and re-installation and everything fit.

Director's Side Notes

Ya know, building an Electric Vehicle, we get the sense that we're doing something good for the environment. Why don't the big car manufacturing giants build them yet? And here we stand.

There are many challenges when building an electric vehicle. Most of them require 'thinking outside the box'. Fortunately, some of us are seasoned in this area. Others, not so much. Then there's the ever useful tool, the internet.

We can price compare, look up information on problems we're having with the car, view other EV builder's vehicles, and ask questions to those more knowledgeable than ourselves. Kudos to the internet and to those who are more seasoned and willing to share their knowledge.

If we all were so inclined and gave it our all in converting an internal combustion engine vehicle into an electric vehicle, the task may be done in a month. However, I consider myself an amateur, and those who are willing to take the task on themselves as individuals. For us, it takes longer. We're approaching the 11th month since the idea of an electric vehicle popped into our heads, and we haven't even installed the motor into the vehicle.

In the end, we convince ourselves, it will all be worthwhile. I agree in this notion. It will be worthwhile. That is because we have demonstrated to those car manufacturing giants that the future of technology resides in alternative fuel methods. These include electric, hydro, bio, air, and more. Our one obstacle that remains is the petroleum giants.

I'm open to suggestions.

Mounting Motor Mount Plate onto Motor

We bought a piece of 3/6" stainless steel sheet metal measuring 12"X24" to use as a motor mount. We cut a square into the sheet metal at one end with a cut off tool as well as drilled 4 holes to match the 4 adjoining holes from the motor.

Finished Right CV Boot

We ordered a CV boot off the internet which arrived April 2nd. By April 4, we were attempting to change the boots. The new CV boot did not fit due to 3 crescent shaped rubber pieces sticking out on the inside of the CV boot. After 2 days of fighting with it, we went to our local auto parts store, bought a new boot for even less money, and hooked it all back together withing a matter of 2 hours (including a lunch break).

I know you can't see it in the picture below, but there are three puncture holes in the boot.