Archive for November, 2007

two steps forward…

Sunday, November 11th, 2007

When you perform this amount of disassembly on a ten-year-old car you’re bound to come across peripheral problems which, if not addressed now, will require attention somewhere down the road. Though it makes sense to take care of them while the car is apart, it always throws a wrench into your carefully-planned scheduling.

Case in point: when testing the motor this week it proved essential to know the car was in neutral, but when I attempted to shift the shifter fell through the bottom of the car. After 2-3 hours of dissection I discovered all that was holding the shifter in place was friction and a bit of glue (yes, glue). So another hour or so was devoted to putting the shifter back together, but in the process I did come across a forum online for Aspire owners. The comments were fairly evenly split between admirers and detractors (”It aspires to be a car” wrote one poster), and in the mix was a poor soul who couldn’t figure out why his shifter had fallen through the floor.

Back to the motor testing. We hooked up the car’s original 12V battery to the motor and darnitanyway if with a few good sparks that sucker didn’t start spinning like a top. Somewhat reassuring as I have had it now for six months and it is getting less accessible by the day. Also accomplished this weekend: cutting the side panels from HDPE for the rear battery box; mounting the controller on its bed of heat-transfer grease; ordering the electrical connectors for recharging the car; ordering a cake pan to act as a water shield for the brush end of the motor.

Front battery racks installed

Sunday, November 4th, 2007

In the past two weeks:

  • Front battery racks installed
  • Engine compartment cleaned out
  • Accessory battery installed
  • About halfway done with component board clips (hold component boards to rack)
  • Cracked steering linkage boot replaced
  • Cracked left turn signal lens replaced
  • Clutch pedal/cable removed

Visiting the Santa Monica Alt Transportation expo kinda lit the fire again. We’re discovering the wonders of self-drilling screws - just load them into a nut-driver of an electric drill, push it up against some sheet metal and voila! Instant gratification.