Custom fuse & relay box installed. ⚡

Printed the outer frame in PETG and used PC for the relay holders for better heat resistance.

Fits in the original location and holds:
• Eaton fusebox for 20 blade fuses
• 5 relays (standard 4 or 5 pin)
• headlight dimmer
• turn signal flasher

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Inverter mounted ⚡

Next to find some thick orange cable...

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⚡ in finnish we'd say "johtohommissa" 😅

Wiring the main 12V harness.

Of course there's a way of making everything complicated, so in my obsession of avoiding unnecessary splices and connectors I went and bought 90deg "flag" spade connectors for H4 sockets only to find those can't be crimped with normal pliers.

Luckily pliers are cheap and nowadays I know how to use an angle grinder.

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Minor progress update again. :)

Got the leaking steering box finally sealed and reinstalled. Steering is working again! Then went on to powder coat and bolt down the gas pedal mount, brake fluid reservoir and finally installed bunch of plugs and made some lasercut cover plates to cover all the (now) unnecessary holes in the floor.

Meanwhile been planning the motor phase connectors and inverter placement. I don't have enough room to comfortably pull the phases out from the top as they normally do, but I *think* I can connect to them from the side via a small maintenance hatch instead. 😏

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Sneak peak. Waiting for some parts to arrive, so woodworking for a change meanwhile.

I want a warm wood finish for the interior instead of the original vinyl leather look. Took measurements, lasercut out of baltic birch plywood. Might still add one or two more coats of oil, but already looking a lot like what I planned! 😊 You really learn a lot when doing all on your own! ...but it's a very slow progress. 😂

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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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Learning how to glue metal to metal. 🤷‍♀️

I've not done any welding before and sparks are scary, but there's nothing in the world that can't be learned. 😎

Grind - Tack - Weld - Cut.
Rinse and repeat.

(Posting this as a test post here and at @sara@mastodontti.fi - Pixelfed really is unhappy currently for me.)

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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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