Brake Systems 2.0

After further consultations, additional replacement parts for the brakes have been ordered.

Meanwhile, this last week, a 12 volt vacuum pump arrived that will be used to replace the lost manifold vacuum previously available from the now extracted internal combustion engine (ICE).  The pump selected was model MES 70/6E and it was purchased ($301) from Metric Mind Corporation (http://www.metricmind.com/category/ev-vacuum-pumps).  It weighs about 1.2 kg and it has a operating noise level of about 58dBA.  It  purrs with a sound level that is very much like a  aquarium air diaphragm pump.  The manufacturer indicates that a 3 amp automotive fuse must be used for the electrical protection of the pump.

Picture DSC 05088 shows the side view of the MES 70/6E.  It is designed to be run with the long dimension oriented parallel to the base of the car.

Picture DSC05089 shows the top view of the MES 70/6E.  There are 3 mounting holes on the base that have rubber/grommets with brass centers to secure the pump to the vehicle.

This pump was highly recommended by Tim Catellier (http://www.evalbum.com/3189 ) and it was shipped immediately by Metric Mind upon placement of a credit card order.    For an additional $8 Metric Mind included a connector plug kit which requires both additional wires as well as the attachment of crimp/solder pins to the leads before it can be used.

Picture DSC05075 that shows the wiring plug kit that required assembly before being used.


O'Reilly Auto Parts offers an equivalent prewired plug with 7” wire leads as part BWD 28423 ($6.99) that was purchased for initial testing with a 12 volt battery. 
 

Picture DSC05086 showing the O'Reilly Auto Parts previously assembled electrical plug that is compatible with the MES 70/6E electrical connections.

Using a research grade vacuum gauge (McMaster Carr part 4105K24) the ultimate vacuum under normal operating conditions was measured at 19.8 inches (495 mm) of Mercury. At this vacuum the pump's internal pressure switch automatically shuts off and then later restarts when the vacuum quality has decreased to 18 inches (457 mm) of vacuum. When the power leads were reversed (per manufacturer’s instructions for temporary testing in a “diagnostics mode”) the ultimate vacuum achieved when the pump ran continuously was 21 inches (533 mm).  The vacuum range delivered by the MES 70/60E is claimed by the manufacturer to be identical to the vacuum produced with a typical ICE.

 

 

 

 

Picture DSC05087 showing research vacuum gauge that was used to measure the operational and maximum vacuum produced by the MES 70/6E vacuum pump.

 

Foundry Castings Returned from the Machinist

Today we picked up the finished adapter plates from the machine shop.  These adapter plates were first reported in this blog 8/16/2012, and now two months later, we have them in hand.  The first three foundry castings were made from David's foundry mold and then a machinist used David's engineering CAD drawings for the bolt and motor placement holes.  We now have the ability to produce these adapters on demand if other EVers need them.   The next step will be to build the drive train and confirm that bolt holes and dowel tube placements are precisely where they should be.

Picture DSCN0541 showing casting after face machining, pushed against large faceplate with live center in tail stock.

Picture DSCN0889 showing active drilling of holes after CNC machine setup and programming.

Picture DSCN0909 showing finished machined surface from the Getrag transmission side view.  The holes   drilled for 14.5 mm orientation dowel tubes are located at about 11:30 and 7:00 (toward mid line).
Holes are 14.5 mm ID and 6.62 mm deep.  

(updated 4/22/2021)

Picture DSC01132 of the Aluminum dowels (2 required).

Dowels were purchased from BMW (part 11117524470 and $1.65) and were Aluminum with a 14.50 mm OD x 12.56 mm ID and 10.72 length.  The edges were beveled on the outside lip.

Picture DSC01134  showing the placement of the pair of 14.5 mm dowels on the transmission side of the adapter plate prior to using a mallet to force them into place.  A full thickness 12.6 mm pilot hole was initially drilled, followed by a 14.5 mm dowel hole that is 6.62 mm deep.  This created an internal  stop so that the dowel cannot be over inserted.

Picture DSCN0910 showing finished machined surface from the motor (Warp 11) side view.  Note that there are 12 mounting holes in the center polished surface.  These holes will allow the Warp 11 to be rotated into a variety of orientations.

DSC01669 side view of the adapter plate.

DSC01671 transmission face side.

DSC01672 motor face side.

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