Back from holiday, finished the final motor mount and there it finally is! 😊

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😵‍💫

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Summoning the 4th state of matter to cut 6mm steel with a press of a button feels like violating some laws of dark magic.

Plasma cutting parts to be welded for the upper motor mount.

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Motor is IN!

Still missing the top mount, some suitable bolts and powder coating but...

IT'S THERE. IT FITS. IT'S ELECTRIC ⚡ ⚡

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Something easier for a change. Measurements from the old worn out kickpanels, lasercut new ones. 😊

Need to find some suitable fabric for upholstery 🤔

Oh and of course saving and cleaning the old stickers...

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Couple of youtube vids later, learning how to use Fusion simulation features. Added more strength to the motor mounts based on the feedback from earlier calculations + simulation environment.

Now stable for:
100kg * 9.81 downwards force (weight of the stack)
280Nm * 7.94 (reduction gearbox) = 2223Nm rotational force

with ~2.4 safety factor. I'd have liked SF >3 but ah well. I don't think this steel will ever see full 280Nm and I'd be more concerned it'll tear the original engine mount rubbers into pieces far before that.

Next up.. steel?

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Quick update about motor mounts.

Lasercut templates from clear acrylic to check that everything fits and oh do they. It's so satisfying to draw things onto the 3D-scan, make templates and find out it's within 0.25mm!

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Polling fedi engineer people before attempting to learn how to calculate this myself. 😄

Mounting the motor like this is going to be alright? Right? 😄 (view from above)

There's going to be 4th mounting point above the stack as well just for the safety. But ideally I want these three to be able to support the motor on their own.

Using the original mounting points and rubber vibration dampener mounts, but slightly concerned about the long beams deflection/yield. Would *not* want to lose the motor onto a motorway!

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Practice time over and on to the real business. 😎

Rear motor mount will attach to the original engine mounting bar rubbers and has two L-brackets to hug the sides of the motor. This will provide a subframe/cradle of sorts for the inverter, charger, etc to stack up next to the motor.

Front motor mount will connect to the rear axle where the transmission nose bolts onto. Still have to figure out 3rd mounting point, preferably above somehow.

I'm trying to design following the original mounting points and avoid making changes to the chassis. Bolt-on is the best. 😅

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Back at it! (Oh and Pixelfed lost my previous pics, ah well, we'll continue as if nothing happened :3)

Lasercut a cardboard template to check my 3D-scan files are indeed correct for the motor mount fabrication. They are. 😊

Next up pulled the steel stock I've had laying around for some months and chopped it to pieces to form the rear motor mount. Metalworking is something I've procrastinated about for too long now, so it's time to finally learn.

Cut some extra pieces from the same stock and tried welding them together. This is uhh... 2nd time in my life I'm holding a MIG torch in my hand now? I wouldn't exactly trust this to hold the motor yet, but it's a starting point!

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No real progress lately; been busy with other projects and decided to take a break from this.

However come spring and better weather, I plan to continue. :)

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More aircon in preparation for the future heatwaves. 😊 Sliding window, that seal was by far the worst to install! Took three tries to get it.

Also check out another vehicle project in local #hackerspace #makerspace recently back on the road again! https://www.youtube.com/watch?v=AZ1qq7INEWA

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3D scanned the entire motor room and the Leaf motor. Should make things rather much easier than good old fashion cardboard aided design.

Many thanks to Arno from https://mekanisaatio.fi 😊

Firing up Fusion 360 for motor mounts in 3... 2... 1...

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👀

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With the wiper stalk slightly modified, it was time to put the steering column back together complete with the steering wheel and the horn button.

And it steers!

Still some minor lash to adjust in the steering box and cambers and tierods are probably all askew.

But it steers!

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Woo my AC is working. 😊

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Taking a brake still. 😊

Plumbing just about done. Steel braided lines back and front for maximum looks. 😎

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Yees! Tesla M3 brake booster fits like it's meant to be in this bus!

...when you install the master cylinder the other way around and turn the whole thing upside down. 🤭

🙃

I'm still slightly amazed that the bolt pattern is almost spot-on and the only issue was with the tie rod blocking the connector. I'd have expected much worse. 🤷‍♀️

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So close, yet so far. 🥲

Tesla Model X/3 brake booster *almost* fits this bus plug-and-play style. The bolt pattern is so close that the VW bolt holes needed barely 2mm of filing in horizontal.

If only that tie rod wouldn't be right in front of the connector.

🤔

🤷‍♀️

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Steering box has a dust shield on top protecting the proper seal from the worst road debris. Turns out, you can't buy that anywhere anymore and mine was cracked pretty badly.

It's not *that* important, but I'd rather still have one. Luckily we live in the future, so it's just a perfect opportunity to learn how to do 3D printing. 😄

With that tiny issue out of the way, steering box and shaft mounted to the van. 😊

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