63 Series IIA 109 PU Hybrid Electric - Page 16 - Defender Source
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  #301  
Old July 2nd, 2015, 11:06 AM
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Don Bunnell
'86 110 3dr ST
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Absolutely nothing wrong seeing Rover chrome and custom milled suspension pieces up:
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  #302  
Old July 5th, 2015, 06:10 PM
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Charles Galpin
'94 D90 ST, '63 SeriesIIA
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I got the rear air springs installed. These line up perfectly, and after a closer look I realize the holes for the turret parts are exactly like the front so my custom pucs are fine.

At maximum compression allowed, it looks like I need 1.5" extension to the bump stops

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They have 10" of travel. Sam for the front although it still doesn't look right to me.
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I zinc plated some bolts for the anti-sway bars. I am waiting for hardware to finish installing the rears and then will take pictures of the anti-sway bars installed
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Bolted on a few more bits before running out of hardware...again.

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  #303  
Old July 5th, 2015, 08:18 PM
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Baller! Looking good, Charles!
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  #304  
Old July 5th, 2015, 09:50 PM
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Bill Adams
66 109 sw 94 lwb
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Nice to see you got the bloom under control. Plating is the shiz.
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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
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  #305  
Old July 6th, 2015, 12:08 PM
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Ron Dade
97/D90 Soft Top
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Great progress, Charles. Looking awesome. Love all the home engineering/fabrication.
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  #306  
Old September 20th, 2015, 09:03 PM
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Charles Galpin
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This thread is overdue for an update, although it doesn't look like over 2 months of progress!

At some point I spruced up the steering box. Replaced the seals and gave it an old change and a coat of paint.

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I also zinc plated the nut and washer, and painted the pitman arm since I had to use a map gas torch to remove the galvy from the splines. I'll take pictures once I get the steering hooked up.

I don't seem to have taken any pictures but I had the drag link and steering arm powder coated a while ago, and today I screwed in the new tie rod ends. It required significant force and it looks like I split the small piece on one side that allows you to turn it and adjust the drag link without undoing the ball joints (RRC setup). So I'll need to lookup that part number and get a replacement.
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  #307  
Old September 20th, 2015, 09:11 PM
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Charles Galpin
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Diff rebuild

Over a protracted period I collected new bearings and HD 4.75 gears for my diffs and rebuilt them. First the bearings

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Then the new crown rings

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  #308  
Old September 20th, 2015, 09:17 PM
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Charles Galpin
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I borrowed Jeff's awesome tool he made to hold the diff and allow you to turn it to the orientation most useful for the task.

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And this is what I ended up for a gear pattern. Still really not 100% sure this is a good pattern, but I'm calling this good.

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  #309  
Old September 20th, 2015, 09:25 PM
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Charles Galpin
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With the diffs done, I could install the front and finish up building out the front axle. I put on the rrc brake bracket but suspect I'll want to get the defender ones.

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I have run into a problem with the brakes. I have bought D90 front brake calipers but they use a larger bolt than the RRC. The RRC uses a M12 1.25 thread bolt, but the D90 calipers use a bolt with a larger shoulder and 1/2" -13 course thread. Not sure what the proper fix is but if I have to drill and tap the hubs to 1/2" -13 it will suck since everything is now mounted.

But being able to put wheels on it allowed me to do a maiden roll!

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Oh, this week i scored some free used LiFeP04 batteries to do some testing and experimenting with. They are a bit janky but hopefully will give me some experience with this chemistry and test some of my gear. I need to pick a direction for a battery management/monitoring system and this would be a good test bed for that too.

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  #310  
Old September 20th, 2015, 09:28 PM
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Charles Galpin
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99% sure it's the RRC arm - is this bad? I have not tried to hook up the steering arm yet.

The box is a manual one from a defender but I don't think it's drop is any different.

Quote:
Originally Posted by JSBriggs View Post
Are you running a Disco or a RRC/Defender arm?

-Jeff
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  #311  
Old September 20th, 2015, 09:45 PM
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Charles Galpin
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Aah, this is the Disco style then as I have tie rod ends on both ends of the rod and just a tapered hole in the arm. Basically flat as well. So maybe it came with the box. I really don't remember.
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  #312  
Old September 20th, 2015, 09:58 PM
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nice! Is that a little Yuasa 6V on the ground by those used LiPos? Those batts are gigantic...
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  #313  
Old September 20th, 2015, 10:12 PM
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Charles Galpin
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Yeah, that's a standard UPS battery for scale. They are huge and heavy - about 30 lbs each I think. 25 of those have the same capacity as 100 of the ones I am getting, although these in series are not high enough voltage to drive my inverter. Who knows, if these test out as good, maybe we'll be seeing a DC motor based wheeling build one day! Think a quick and dirty conversion of a disco maintaining the transmission and doing nothing but pulling the motor and putting in an electric motor and batteries. No rehab or anything other than saws work where desired :0.
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  #314  
Old December 26th, 2015, 09:07 PM
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1960 Series 2a Hybrid
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Glad to see you're still working on this conversion.
Are those 400ah Winston cells? What on Earth are you going to do with those?
I assume you're using CA100's? Have you bought them yet?
If you haven't bought a charger or DC-DC converter yet, salvaged Volt parts are cheap and will work perfectly for you.
I started working at EVTV a couple months ago. If you need help with anything just let me know!

Bill
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  #315  
Old December 28th, 2015, 08:45 PM
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Charles Galpin
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Yes, 400ah Winstons. Really just using them to learn and test stuff (got them free). Santa brought me a powerlab which I plan to use to start charging and measuring them, and then try bottom balance them.

I have not bought my call 100ah yet. Holding off till the very end since I'm going so slow. I have not ruled out leaf batteries or other options since they are so expensive, but realistically I need to get this thing done so avoid too many diversions

I have the DC-DC convertor but still need a charger. Holding off on that too, but have my heart set on a liquid cooled one so I can mount it under my front battery box or under the motor - plenty of room but a harsh environment. I was planning on a bru$a but will look into the volt stuff too.

I haven't had time to keep up with Jack's videos but did watch one a couple weeks ago when doing my year end book keeping and was pleased to see you on (although I hadn't made the connection to you here). Good to know, and congrats!
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  #316  
Old December 28th, 2015, 10:34 PM
enzorover
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Bill
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Well, bottom balancing is like watching paint dry...BBing 400ah cells is watching for a very, VERY long time.
If your cells are sitting at 3.3v it will take about 8-10hrs to get them down to 2.5v using a 250w resistor.
I've never used a Powerlab but don't underestimate the amount of energy in those cells...keep a close eye on the voltage in your 12v battery.
Leaf cells are more energy dense and about 8x cheaper than LiFEPO4 cells but they're also more dangerous if something goes wrong. They can't really be bottom balanced so need some sort of low-voltage disconnect system. If the pack over discharges, it's possible that the weakest cell could go to 0 which, in turn, could create an explosive over charge situation. <-- That's what happened to Jack's shop...
It's no reason to avoid them. They really are great value and plentiful. They just require some awareness and respect.
Tesla modules are becoming available also and are more energy dense than the Leaf.
85kwh pack for less than 100 CALB's: 2013 Tesla Model s P85 Battery 85KWH 1014114 00 B 16 458 Miles | eBay
Your 109 could have a 200mi range.
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  #317  
Old December 30th, 2015, 09:05 PM
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Charles Galpin
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Haha, who knows - i might be able to buy direct from the giga-factory by the time I am ready for batteries. But seriously, I have decided the very last thing I am doing is buying the batteries. I already have to redo the front battery box, so why not the rear too
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  #318  
Old March 29th, 2016, 09:20 AM
enzorover
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Any updates??
Summer cometh!
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  #319  
Old March 29th, 2016, 06:12 PM
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Charles Galpin
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Sadly none. Still barely keeping my head above water.
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  #320  
Old May 15th, 2016, 09:11 PM
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Charles Galpin
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Some progress

Finally some progress, and hopefully the beginning of more, and not an anomaly.

This week I tore down the LT230 and gave it a bath. Just a clean and re-seal since it's in great shape otherwise. Will get it put back together with new o-rings, seals, gaskets, high capacity sump, and flanges this week.

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I still need to powder coat the brake drum and locate the galvanized backing plate before being able to mount the drum brake, as well as drill and tap the sump for a temperature sender. I probably need to buy another difflock switch and breather too if I can't find them
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