The Corolla is for Sale on Ebay

We highly encourage our blog readers to purchase the Corolla!



http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=180698263353

Presentation

On Wednesday, we presented the Electric Corolla to HRA where it was met with a warm welcome.  It was quite exciting to drive it onto the stage.  Many people had questions after the presentation, so we stayed back for almost an hour and chatted.  Today, we picked up the new and revised fairplay charger that does not catch on fire.  See the presentation video below!














Below is just the video from the presentation (better quality, project video without presentation)

Trek to School

Today we made the 21 mile trek to school. After strapping big cushions to the front of the Discovery to aid the Corolla at traffic lights on busy roads, we set off. The Corolla maxed out at 55mph and made it to school without a problem. After letting the controller cool off some, it did not seem as though the pack was entirely depleted. It may go 30 plus miles on a charge. Anyways, the presentation and unveiling is Wednesday evening in the HRA Auditorium.

Video Trailer

Here is a trailer for the final video that Aidan and I will finish making this weekend.  We finally bought and installed a new transmission!  Speeds of 35-40 on flat land are no longer a problem.  Range test tomorrow afternoon with a video to follow!

Weekend of Progress

This weekend, analyzed the removed transmission and started our video.  Thanks Mike Unger, for helping us disassemble and make sense of the transmission issues!  Here are some pictures of the completely worn down and soon to be replaced transmission along with our senior project movie trailer.

Transmission Removal and Filming!

Today we removed the transmission.  Thanks to the airport for letting us borrow their air tools.  We also started filming.  Here is one of the videos we made for the project and some pictures of the transmission removal progress!

Filming

The transmission removal attempt was a bust... We will borrow the airport's air tools tomorrow.  We will also begin filming for what is destined to be a most excellent senior project!

What's Been Happening

Sorry for the period of inactivity.  I can assure you that we have been very active!  We have the title now and are beginning the process of registering the car.  We are currently hunting for a transmission locally, but may have to resort to an ebay purchase.  More on the transmission and registration next week!

Minor Upgrades

Aidan and I went shopping for the Corolla yesterday.  We bought a charger (thank you Middle Peninsula Golf Carts) and then raided the clearance table at Advance Auto Parts.  I bought fuzzy dice and a can of metallic grey paint to replace the fading green grill paint, while Aidan bought headlight restoring stuff and a grease gun.  We then repainted the grill and plastic thing that says "Corolla" on the back, wired in the new charging port, and "restored" the headlights.  Great success!  Next on the to do list is to replace the transmission...

Problems Solved!

We solved the potentiometer issues, and Stan of Middle Peninsula Golf Carts wired up a charging port and let us borrow a charger.  It turns out that we had the forward/reverse control wires coming from the potentiometer wired to the controller.  We simply plugged in the other white/black wires running from the potentiometer and our problem was solved!  Thank you very much to Middle Peninsula Golf Carts for advising us, wiring up the motor controller, and allowing us to borrow a charger.

We later drove to Mr. Joyce's house and Marshall's house.  After the trips, the Corolla was almost completely dead, so it received its first charge!

The First Drive Under Electric Power

Today, Aidan and I had a very exciting day. We left school early to pick up a trailer so we could tow the car. It turns out that the trailer was too much for the poor little Discovery, so we rented one from uhaul. We then towed the electric car from w-burg to our friends at Middle Peninsula Golf Carts. There, they wired up the control and told us how we could program it at home. Well, after some trial and error, we wired everything up properly and were able to connect the controller to the computer through the antiquated "Comm port." Well, we are immensely pleased. We have to sort out the controller's current on/off nature and perhaps, later, the transmission issues. The videos speak for themselves!

Wiring up the car

We are at middle penninsula golf carts wiring up the car.  It's a bit different, so they are using the time tested trial and error method.  We had to rent a trailer that was self braking, so we could tow it with the discovery.  Thank you to Mike, though, for offering his trailer.

Buying more cable

Aidan guestimated wrong, so we bought 13 more feet of cable!

Wiring!!!!!

This weekend, I used the aforementioned cable lugs from NAPA and wired the battery pack together. We still need to wire the pack to the solenoid, the solenoid to the controller, and the controller to the motor. I also mounted the potentiometer box so that the cable throttle can now be translated into electric motor controller language. We are almost there. The only thing left to buy is the charger. After that, off to see if we can get a paint job donated as the paint looks really sad.

Cable Lugs and Solenoid

Today we picked up 25 copper cable lugs from NAPA that will connect the the cable to the batteries!  We needed 23 but figured that 2 more wouldn't hurt.  We also bought a solenoid from Middle Peninsula Golf Carts.  We'll probably wire it up sometime next week!

Mounting the Batteries... Part Deux

We finished mounting the batteries!  Two days and 20 pounds of angle iron later, we have a nice setup that evenly distributes the weight.  We are so clever!  The mounts look rather simple, but they took so much effort.  We had to construct and support the trays.  We then had to "massage" (cut bits off of) the grill and headlight so that the batteries would fit.  We also moved the horn a few inches.  Now that it is shoved up against the grill, it makes a very endearing little squeak.  Anyway, now all of the heavy lifting is done.  We just have to buy some wire, buy a charger, and visit Middle Peninsula Golf Carts so they can help us wire it up.

Mounting the Batteries... Part 1

Today we mounted the back five batteries.  We used angle iron to squeeze the batteries together and then secured them from side to side with a long bungee cord.  As you can see from the video, it looks pretty professional :).  More to come tomorrow when we finish mounting the batteries in the front bumper.  We could fit all eight in the trunk, but we are distributing them for suspension happiness/weight distribution purposes.

Batteries!

We picked up and paid for the batteries and controller.  We then placed the batteries in the car to sort of mock the weight distribution when they are mounted.  The poor Corolla's suspension will indeed support the batteries.

Batteries

So, today after a period of relative inactivity, we paid for and brought home the batteries and the motor controller. By far the most expensive part of the build, the battery pack consists of 8 unpleasant to move 6 volt lead acid deep cycle batteries. Three will be mounted under the hood on the front chassis cross-member and the other 5 will be mounted in the trunk. The videos chronicling this exciting day will soon be posted.

Electric Corolla Gets New Shoes

Today, we bought two used tires to replace the "Winston Classics."  These have the benefit of no steel belts hanging out of the side.  Now we might pass the inspection.  These tires have a bit taller sidewall, but they were cheap!

Look! Tread!

New(to us) Rubber!

Happy Holidays

Sorry about the lack of updates, we've been busy celebrating the holidays.  We hope to go tire shopping on Saturday to replace the bald tires.  That's really the only obstacle preventing the car from passing the state inspection :).