63 Series IIA 109 PU Hybrid Electric - Page 11 - Defender Source
Defender Source  

Go Back   Defender Source > Build-up's, Projects & Registry Profiles > Truck Build-up's & Restores


Reply
 
Thread Tools
  #201  
Old October 5th, 2014, 11:06 PM
Rover Lover's Avatar
Rover Lover
Status: Offline
Ron Dade
97/D90 Soft Top
Member
 
Join Date: Apr 2013
Location: Washington, DC
Posts: 307
Impressive work!
Reply With Quote
Sponsored Links
Advertisement
 
  #202  
Old October 6th, 2014, 06:09 AM
o2batsea's Avatar
o2batsea
Status: Offline
Bill Adams
66 109 sw 94 lwb
Member
 
Join Date: Jul 2009
Location: kensington md
Posts: 6,495
Registry
Wait, I see feet with actual shoes on and no flip flops.
__________________
Bill Adams

1966 109 5 door wagon 300Tdi "spermaceti fueled"
1994 RRC LeWiB "ruining the air behind me"
1968 2A 88

All my troubles are Rover
Reply With Quote
  #203  
Old October 6th, 2014, 06:18 AM
The Dro
Status: Offline
Dro
1988 Ninety
Member
 
Join Date: Jan 2010
Location: Annandale, VA
Posts: 6,682
Registry
Quote:
Originally Posted by o2batsea View Post
Wait, I see feet with actual shoes on and no flip flops.
He's at TechShop.
__________________
Mine is NTO... It was new, Now I'm Taking it Off.
Quote:
Online speculation will not replace onsite inspection.

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.


To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.


To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
Reply With Quote
Sponsored Links
Advertisement
 
  #204  
Old October 6th, 2014, 11:46 AM
revtor's Avatar
revtor
Status: Offline
Steve Maietta
1969 IIA 88" Bugeye
Member
 
Join Date: Sep 2006
Location: Northern NJ, USA
Posts: 817
Registry
Keep up the good work! Whats the story on the CNC router?
__________________
"Yeah, make sure its a flatbed...."
Reply With Quote
  #205  
Old October 6th, 2014, 08:37 PM
cgalpin's Avatar
cgalpin
Status: Offline
Charles Galpin
'94 D90 ST, '63 SeriesIIA
Site Team
 
Join Date: Jan 2004
Location: South Riding, VA
Posts: 11,623
Registry
Yeah, have to play by the rules to play with the tools at tech shop. It's a torch mill, although I did the facing on a Jet (non-CNC mill). I don;'t know the model numbers offhand.

Ed like anything else there you have to take the Safety and Basic Usage (SBU) class to use it which is a bit pricey, but otherwise it's pretty easy to use.
__________________
Quote:
Originally Posted by pendy
I'm here for the D's
Reply With Quote
  #206  
Old October 16th, 2014, 11:26 AM
enzorover
Status: Offline
Bill
1960 Series 2a Hybrid
Member
 
Join Date: Dec 2013
Location: Cape Girardeau, MO, USA
Posts: 18
Fantastic build! I built a Hybrid SIIa when I was in England. I've since sold it to help fund the conversion of my Ranger. I kind of regret selling it now as it would have made a very cool, although not particularly aerodynamic or light, conversion.

Good choice on the motor and luckily the GEVCU is proving to be quite reliable and programmable.

What charger and DC-DC converter are you using? I assume you'll be using CALB cells? What will you be using for gauges? I went to EVCON this year and a guy had a converted Datsun truck with analog Ammeter and Volt meter. I can't remember where he bought them but they looked great.

I'll be following this thread with great interest!
Reply With Quote
  #207  
Old October 20th, 2014, 10:59 PM
cgalpin's Avatar
cgalpin
Status: Offline
Charles Galpin
'94 D90 ST, '63 SeriesIIA
Site Team
 
Join Date: Jan 2004
Location: South Riding, VA
Posts: 11,623
Registry
Thanks Bill

I haven't bought a charger, or EVSE yet but will likely put something together from an open source kit. Actually this is probably on my short list before the end of the year, leaving batteries as the real big expense next year. I am torn between going slow/low tech initially to keep costs down, or the full monty level 3 out of the gate. L3 chargers are damn expensive though, even just to build!

I have a 800W Chennic DC-DC convertor

I have made the battery boxes to fit 100 x CALB LiFePo4 100Ah batteries

Not sure about the gauges yet. My gut says I can retrofit the stock multi-function gauge to show amps on the ammeter and state of charge on the fuel gauge, and use a small motor and PWM to drive the speedo. Otherwise a VSS and a VDO speedo would work. I'd like it to look simple/stockish at first glance, and then a stealth/secure/waterproof install of a tablet for for in depth info and access to the GEVCU.

Things are going slow but hope to get into the EV side of things in depth next year once I am back to a rolling chassis, maybe maybe EVCON in a year to two.

Any pics of your hybrid?

charles
__________________
Quote:
Originally Posted by pendy
I'm here for the D's
Reply With Quote
  #208  
Old October 21st, 2014, 08:17 AM
enzorover
Status: Offline
Bill
1960 Series 2a Hybrid
Member
 
Join Date: Dec 2013
Location: Cape Girardeau, MO, USA
Posts: 18
I'm just going to use J1772 L2 charging on my Ranger with the Brusa 3.3kw charger. Not the cheapest charger but it's a beautiful piece of hardward. Yeah it would be nice to charge faster but 99% of the time I doubt I'll need to. If you have the cash, you can buddy several Brusa's together... I had an electric motorcycle (Zero FX) with about 50mi range and that suited my daily needs just fine. My Ranger has two packs of 45 CALB 100's and I hope to get about 80mi range.
Attached Thumbnails
Click image for larger version

Name:	4.jpg
Views:	179
Size:	144.0 KB
ID:	105385   Click image for larger version

Name:	24.jpg
Views:	172
Size:	130.7 KB
ID:	105386  

Click image for larger version

Name:	123456.jpg
Views:	192
Size:	128.3 KB
ID:	105387   Click image for larger version

Name:	P1020470.jpg
Views:	184
Size:	95.6 KB
ID:	105388  

Reply With Quote
  #209  
Old October 21st, 2014, 09:24 PM
cgalpin's Avatar
cgalpin
Status: Offline
Charles Galpin
'94 D90 ST, '63 SeriesIIA
Site Team
 
Join Date: Jan 2004
Location: South Riding, VA
Posts: 11,623
Registry
Nice looking truck!

Yeah the truth is slow charging should be all I need. We'll see

I'm hoping for about 80 mile range as well - if anything, just to be able to say I have a greater range than a leaf (since I'm spending more than a leaf in the drivetrain alone)
__________________
Quote:
Originally Posted by pendy
I'm here for the D's
Reply With Quote
  #210  
Old January 1st, 2015, 05:34 PM
cgalpin's Avatar
cgalpin
Status: Offline
Charles Galpin
'94 D90 ST, '63 SeriesIIA
Site Team
 
Join Date: Jan 2004
Location: South Riding, VA
Posts: 11,623
Registry
Amazingly it's almost a year since I left off working on the rear frame mods. I wanted to flip the frame upside down before working on the rear skid and finishing up the frame mods, but didn't want to have to assemble it all again afterwards. It's taken me this long to sort out other stuff, but I am now at th point where I can strip the suspension and finish up the frame work and get this stuff to galvy!

So the last thing that needed the suspension was the rear anti-sway bar. Since this is a mall crawler I favor less body roll over extreme articulation so I am putting ant-sway bars on both the front and the rear. Due to my frame mods I needed to widen it and figure out where the bushing mounts should go.

Ok, so this is what I had to work with

Click image for larger version

Name:	IMG_2643.jpg
Views:	164
Size:	84.0 KB
ID:	109969

The top two are actually front sway bars, one I bought years ago with the intention of putting it on my D90, the other donated by Carlos Z (including new dog bones and hardware!). The beefy one was donated by Zack G, and the dinky looking one on the bottom is a stock 109 bar thanks to Bill A. Thanks to everyone, but since I only had one pair of the same diameter the choice was easy - I used the two fronts.

Click image for larger version

Name:	IMG_2645.jpg
Views:	152
Size:	86.3 KB
ID:	109970 Click image for larger version

Name:	IMG_2646.jpg
Views:	159
Size:	85.4 KB
ID:	109971

I first used a bit of DOM tubing left over from Ed's drag link project to mock it up and figure out the best width

Click image for larger version

Name:	IMG_2647.jpg
Views:	147
Size:	91.5 KB
ID:	109972 Click image for larger version

Name:	IMG_2648.jpg
Views:	148
Size:	83.2 KB
ID:	109973

I then sacrificed one of the sway bars to make an extension and prepped for welding. I forgot to take any pictures of the welding but I used basically the same approach I used on the steering.

Click image for larger version

Name:	IMG_2649.jpg
Views:	154
Size:	93.2 KB
ID:	109974 Click image for larger version

Name:	IMG_2650.jpg
Views:	147
Size:	77.1 KB
ID:	109975

And here is a test fitting it. So now I feel I can pull the suspension and flip the frame around as needed to do the finish welding, plating, gusseting I need to do, as well as weld up the skid plate!
__________________
Quote:
Originally Posted by pendy
I'm here for the D's
Reply With Quote
  #211  
Old January 1st, 2015, 08:03 PM
Rover Lover's Avatar
Rover Lover
Status: Offline
Ron Dade
97/D90 Soft Top
Member
 
Join Date: Apr 2013
Location: Washington, DC
Posts: 307
Go Charles, go!!!
Reply With Quote
  #212  
Old January 11th, 2015, 07:37 PM
cgalpin's Avatar
cgalpin
Status: Offline
Charles Galpin
'94 D90 ST, '63 SeriesIIA
Site Team
 
Join Date: Jan 2004
Location: South Riding, VA
Posts: 11,623
Registry
Plugging away at my pre-galvy checklist. Lots of Frame flipping to avoid welding on my back

Click image for larger version

Name:	IMG_2662.jpg
Views:	174
Size:	110.3 KB
ID:	110691 Click image for larger version

Name:	IMG_2669.jpg
Views:	150
Size:	104.7 KB
ID:	110697 Click image for larger version

Name:	IMG_2679.jpg
Views:	151
Size:	106.0 KB
ID:	110703

Rear battery box area needed a bunch of finish welding and skid retainer nuts. Tigged up rear skid and modified hitch to work with it.

Click image for larger version

Name:	IMG_2664.jpg
Views:	155
Size:	104.6 KB
ID:	110692 Click image for larger version

Name:	IMG_2666.jpg
Views:	154
Size:	92.2 KB
ID:	110694 Click image for larger version

Name:	IMG_2668.jpg
Views:	133
Size:	60.7 KB
ID:	110696

Click image for larger version

Name:	IMG_2670.jpg
Views:	147
Size:	104.4 KB
ID:	110698 Click image for larger version

Name:	IMG_2671.jpg
Views:	153
Size:	99.1 KB
ID:	110699

Click image for larger version

Name:	IMG_2676.jpg
Views:	148
Size:	68.9 KB
ID:	110701 Click image for larger version

Name:	IMG_2677.jpg
Views:	138
Size:	72.8 KB
ID:	110702 Click image for larger version

Name:	IMG_2681.jpg
Views:	154
Size:	99.9 KB
ID:	110705

Added gussets where I shortened the frame

Click image for larger version

Name:	IMG_2665.jpg
Views:	148
Size:	87.7 KB
ID:	110693Click image for larger version

Name:	IMG_2672.jpg
Views:	133
Size:	95.3 KB
ID:	110700 Click image for larger version

Name:	IMG_2680.jpg
Views:	143
Size:	88.8 KB
ID:	110704

Added front anti-sway bar mounts.

Click image for larger version

Name:	IMG_2667.jpg
Views:	131
Size:	94.1 KB
ID:	110695


Modified series bumper to mount to the 110 frame horns (shorten the mounting tabs).

Click image for larger version

Name:	IMG_2682.jpg
Views:	155
Size:	93.8 KB
ID:	110706

I am going to make a hatch in the tub floor to be able to access the rear battery box, so need to make a frame around the hole and needed to modify a tub support to be able to have a lip that the hatch can sit on and screw into. I added some pads and made a die to press indents into then tabs

Click image for larger version

Name:	IMG_2638.jpg
Views:	137
Size:	89.5 KB
ID:	110707 Click image for larger version

Name:	IMG_2639.jpg
Views:	139
Size:	83.1 KB
ID:	110708

Click image for larger version

Name:	IMG_2640.jpg
Views:	133
Size:	75.7 KB
ID:	110709 Click image for larger version

Name:	IMG_2641.jpg
Views:	137
Size:	82.7 KB
ID:	110710 Click image for larger version

Name:	IMG_2642.jpg
Views:	141
Size:	87.2 KB
ID:	110711

Lots more to do, but the end of the month is looking realistic for a galvy run!
__________________
Quote:
Originally Posted by pendy
I'm here for the D's
Reply With Quote
  #213  
Old January 11th, 2015, 10:48 PM
enzorover
Status: Offline
Bill
1960 Series 2a Hybrid
Member
 
Join Date: Dec 2013
Location: Cape Girardeau, MO, USA
Posts: 18
Coming along!
It's been said that once the battery box(es) are installed you're 90% done. I can confirm that with my Ranger. Once those were established, it was child's play getting the rest sorted out. All the high voltage wiring was simple. The 12v was surprisingly of a pain in the a$$.

Are you planning on heating the cells? I thought about it, and still might one day, but since I don't have a heater (just heated seats), I doubt I'll be driving much when temps fall way below freezing...

Keep up the great work!
Reply With Quote
  #214  
Old January 11th, 2015, 11:02 PM
don's Avatar
don
Status: Offline
Don Bunnell
'86 110 3dr ST
Member
 
Join Date: Sep 2007
Location: Rumson, NJ
Posts: 4,271
Registry
Looks really good Charles! Very nice work all around. Love that die setup you did.
Reply With Quote
  #215  
Old January 12th, 2015, 05:00 PM
sonoronos's Avatar
sonoronos
Status: Offline
Ed
None
Member
 
Join Date: May 2010
Location: Arlington, VA
Posts: 5,524
Registry
pm sent re: galvy run
Reply With Quote
  #216  
Old January 12th, 2015, 05:07 PM
cgalpin's Avatar
cgalpin
Status: Offline
Charles Galpin
'94 D90 ST, '63 SeriesIIA
Site Team
 
Join Date: Jan 2004
Location: South Riding, VA
Posts: 11,623
Registry
Quote:
Originally Posted by enzorover View Post
Coming along!
It's been said that once the battery box(es) are installed you're 90% done. I can confirm that with my Ranger. Once those were established, it was child's play getting the rest sorted out. All the high voltage wiring was simple. The 12v was surprisingly of a pain in the a$$.
Sadly this work will put me at about the point of strip down on a "normal" build. But yes I keep telling myself I should have a fairly quick spurt of progress getting it back to a rolling chassis with the drivetrain installed but then I have to do some body wrk and paint and assemble the whole thing on top of the electrickery.

I think I'll make my own 12V harness since everything else is custom anyway. Nothing has been cheap, so I have no expectations that the wiring harness will be either. My HV wire is due to arrive tomorrow - only $750 for about 40' worth. LOL. But with that I can do my final frame mods

Quote:
Originally Posted by enzorover View Post
Are you planning on heating the cells? I thought about it, and still might one day, but since I don't have a heater (just heated seats), I doubt I'll be driving much when temps fall way below freezing...
No specific plans but I should have room to insulate both inside and outside of the boxes if needed, and heating pads are thin. But probably not initially.
__________________
Quote:
Originally Posted by pendy
I'm here for the D's
Reply With Quote
  #217  
Old January 12th, 2015, 06:22 PM
enzorover
Status: Offline
Bill
1960 Series 2a Hybrid
Member
 
Join Date: Dec 2013
Location: Cape Girardeau, MO, USA
Posts: 18
If you're not afraid of spending a little money and want a nice looking harness, check out Autosparks. They're a UK company who specialize in harnesses. http://www.autosparks.co.uk/index.php?cPath=59_63_339

I used a Painless Wiring harness from Summit on mine. I had to do quite a bit of modification since I was running a diesel but it worked ok. In the end though I don't think I saved any money and suffered in the looks department.

If I ever do put heaters in the boxes, I'm going to run them between the battery "fat sides" so I can essentially heat two cells at once.

What size cable are you using? I used 1/0 for short runs and 2/0 for back to front runs. I used MUCH more than I expected so don't be surprised if you run out!
Reply With Quote
  #218  
Old January 12th, 2015, 06:36 PM
cgalpin's Avatar
cgalpin
Status: Offline
Charles Galpin
'94 D90 ST, '63 SeriesIIA
Site Team
 
Join Date: Jan 2004
Location: South Riding, VA
Posts: 11,623
Registry
I'll think about it but all I'd be using untouched are the running lights, brake lights, and maybe headlights since I am going LED. I'd want to add hazards, possibly a dome light for the hard top, and then other custom low voltage EV stuff. Seems silly to bother with a harness.

I went overkill - 4/0 for the long runs - the fancy XRAD XLE in orange. I don't want any losses and it's going to be in the frame so want it to stay cool (and handle any heat if any is generated).
__________________
Quote:
Originally Posted by pendy
I'm here for the D's
Reply With Quote
  #219  
Old January 12th, 2015, 06:48 PM
enzorover
Status: Offline
Bill
1960 Series 2a Hybrid
Member
 
Join Date: Dec 2013
Location: Cape Girardeau, MO, USA
Posts: 18
Wow! You did go overkill. 4/0 with a 335v system is crazy! But what the hell, it's a Land Rover and unless you're trying to shave pounds, I don't guess you can really go too big.
Have you ever seen 4/0? That stuff is ridiculous!
Reply With Quote
  #220  
Old January 12th, 2015, 08:14 PM
o2batsea's Avatar
o2batsea
Status: Offline
Bill Adams
66 109 sw 94 lwb
Member
 
Join Date: Jul 2009
Location: kensington md
Posts: 6,495
Registry
I'm going to wire Charles' truck for lights to be sure he doesn't fry himself.
__________________
Bill Adams

1966 109 5 door wagon 300Tdi "spermaceti fueled"
1994 RRC LeWiB "ruining the air behind me"
1968 2A 88

All my troubles are Rover
Reply With Quote
Reply

Lower Navigation
Go Back   Defender Source > Build-up's, Projects & Registry Profiles > Truck Build-up's & Restores

Tags
109, series

Thread Tools

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off


Similar Threads
Thread Thread Starter Forum Replies Last Post
Brake options for my 109' IIA hybrid electric cgalpin Series Technical Discussions 13 July 30th, 2013 02:14 PM
Odd, Rare, and heavy Series Stuff FS "NOS" SafariHP For Sale - Parts 8 May 12th, 2012 12:15 PM
1965 Land Rover Series IIa 109 Frame-up Restoration - $100,000 (Asheville, NC) rijosho The Flea Market 11 September 18th, 2011 01:58 PM
67 Series IIA 109 5 Door C-Delta For Sale - Vehicles 1 August 10th, 2006 02:40 AM


All times are GMT -5. The time now is 10:11 AM.


Copyright