Set of Azure Dynamics parts + BMW E30 for sale

Set of Azure Dynamics parts + BMW E30 for sale

Due to a change in priorities, I need to sell the parts I have gathered for my BMW E30 conversion. 

These parts will suit any small to medium sized car conversion, or the E30 that is also for sale (see below). Using direct drive on the BMW the 0-100 time is calculated at about 7 seconds depending on final drive ratio. With a gearbox, even quicker.

All parts are located together in Sydney. You don’t have to worry about group buys, import duties and freight costs. I have done it all for you. 

The price is $8500 for the complete set of parts. This is the all up cost including shipping etc. from around the world. If you add up these prices with similar parts from the EVTV store, it will come to about the same price, and you still have to ship the parts to Australia.

Shipping out of NSW can be quoted separately.

These parts have been selected especially to go drag racing and beat other 80’s - 90's cars such as the BMW E30. The idea is to use enough battery to provide just less than 400V at top of charge and sufficient amps to draw full power for 10 seconds. The high discharge ‘red’ headways are ideal. A little heavy, but fail safe, unlike prismatic and pouch cells. 

This kit, in a light E30 or a Suzuki Cary will fly down the drag strip, or just have some fun at the lights.

Here is what you get:
Azure Dynamics / Siemens water cooled induction motor model 1PV5138-4WS14
. This motor is good for about 100kW and 300 newton meters at 300 volts. I am sure it can be overclocked at least by 10%. Specs: http://store.evtv.me/proddetail.php?prod=1PV5135

Vaxo motor shaft coupling for attaching to a drive shaft or clutch plate if using a gearbox.

Azure Dynamics DMOC645 controller – Already Programmed (controllers usually come un-programmed and normally require a CAN programmer worth several hundred dollars to buy). This controller has an upper voltage limit of 400 volts. If you use 330v of batteries you will be able to increase the motor power and torque by about 10%. There is a lot of support for the motor and controller available from the ev.tv forums. http://store.evtv.me/proddetail.php?prod=DMOC645 

TC Charger 2kW TCCH-312-5.5 Programmable up to 417V & 5.5A, CAN-Bus battery charger. I can even provide a working Arduino, LCD and CAN adaptor with source code to get you started.

Azure Dynamics air conditioning compressor with CAN bus commands documented. I spent quite some time locating the CAN documentation for this unit, saving you the pain. These are also used in the iMiEV in case you need to compare with a working unit. 

2 x Azure Dynamics water pumps. One for motor and controller cooling, the other for the cabin heater.

12 v Brake vacuum pump x 2. One rotary vane as used in Volvos. One Azure Dynamics piston. Your choice which to use, and which to sell.
Brake vacuum switch – adjustable with hysteresis.

Stainless steel bottle for brake vacuum.

Azure Dynamics water heater. This is for heating the cabin of the vehicle and required for demisting the windows.

Set of male and female J1772 connectors for the charging. This is preferred as you can use a commercial charging station, or with the provided cable, charge at home.

2 x Kilovac contactors. http://store.evtv.me/proddetail.php?prod=EV200AAANA

High current MES-DEA 1000W DC-DC. This is a very professional unit rated at 60A output. Many are 40A or less and are simply not up to the task of driving the vehicles 12 volt electrics for any length of time at night with lights, fan and wipers running. This unit will run your 12 v electrics with all accessories running. http://www.metricmind.com/data/mes_dcdc.pdf

BMW Accelerator pedal. This is an awesome unit. Easy to mount and use with your driver interface. No more unreliable throttle pots.
Details of how to drive the various parts are located on my blog http://malfunction.faed.name

Just add a driver interface such as http://rechargecar.com/macchina, batteries and BMS. My preference is Headway batteries and Batrium BMS for ease of use and local support.

For a further 4k you can buy my white ’91 BMW 318i E30 to convert. This car is currently registered in NSW. It has been my daily driver for the last 3+ years. This car has no visible rust and is a pleasure to drive. The suspension is top notch, has new brakes all round and a M40 motor in great condition you can sell to recoup some of the cost. If you buy the car, I will also give you a factory manual steering rackso you don’t need to worry about a power steering pump. I will also include a Getrag 240 gearbox in case you want to use the output shaft or the gearbox. This also allows you to make an adapter plate before pulling the car apart.

If you buy the whole lot for $12,500, I can load up the car with the parts and deliver for free anywhere on the east coast and fly home.

Please phone 0409 601 747 or email Malcolm@faed.name should you be interested.

First had experience with a C5 at Sinclair in the UK

From: http://www.eevblog.com/forum/blog/eevblog-501-sinclair-c5-electric-car-teardown-test-drive/30/

Re: EEVblog #501 - Sinclair C5 Electric Car Teardown & Test Drive

« Reply #37 on: Yesterday at 08:31:10 PM »

Oh man! That's made my day. Let me take you back... back... back...

I worked for Sinclair Research in the mid-80s as a snotty-nosed teenaged Z80 programmer. I joined the day the C5 launched and worked initially in Sinclair's London office (a tiny place with just Clive, his secretary, his father and me - it's a long story...). So I came out of work and there outside the office was the C5 that Clive had been driving at the launch event - widely covered on the telly.  But, nobody knew what to do with it - it was a Friday afternoon, it wouldn't fit through the doorway into the office and you couldn't just leave it there. So light, someone could have picked it up and walked away with it.

"I know!" I said. "I'll drive it home and look after it over the weekend!"

Clive looked dubious "Are you sure?" he said, "It's rush hour, it's London..."

"You've just been on the TV telling everyone how safe it is," I said (teenagers, eh?). "What can go wrong?"

"Errr... OK" he said. What else could he have done?

So I drove it from Chelsea to Chiswick through the London rush hour traffic. Got a lot of attention - after all, it'd had been on the TV all day - and it felt really good.

Until I got to Hammersmith, about three miles from the office and about two from home, when the battery ran out. The advertised range was not quite working out... peddling it (with no gearbox) all the way home was not nearly as much fun.

"Yes," said Clive on the Monday. "There may be some bugs to work out..." Can't remember how we got it back - I think by van.

Some more background on it: it was designed by a couple of chaps at Milton Hall, home of Sinclair Research's Metalab in Cambridge, in conjunction with various suppliers. The P. Newman who co-authored the Unofficial C5 document is Perran Newman, who became my boss at Sinclair after I moved to Cambridge; we worked together on a few projects, including the Pandora portable Spectrum (yet another story).

The "washing machine" motor was in fact a variant of one used for electric torpedoes. The ULA was a typical Sinclair component; the Ferranti ULA in the ZX81 was the first such in any consumer device, and Sinclair had a preference for them over other solutions. It was possible - although I never took part - to put two batteries in series and go very fast indeed, I think the unofficial record was 30 MPH, if you didn't do it for too long. Sinclair engineers were an eccentric bunch, and did things like go jousting in muddy fields in Citroen 2CVs.

But so much on it was just too pared back - the nylon gears that stripped, the batteries that were just too wimpy, those brakes... and, yeah, the British weather. There was a sort of cagoule which clipped around the front of the driving space, but that made you look even more like Davros than before.

Happy days.But it was a doomed project... now, the C10...

Dave from the EEVblog goes for a hoon in my Sinclair C5s

Yours truly messing around with C5s on EEVblog #501 – Sinclair C5 Electric Car Teardown & Test Drive http://goo.gl/fb/CJG5O 

My first CAN bus project.

My first CAN bus project, controlling a TC Charger (Elcon) using CAN bus from an Arduino. I can dial up the voltage and current required, and display status flags of the charger isn't happy.

:-)

Now for a crash course in 3D modelling and 3D printing to make a nice enclosure.

It is the 417V version charger but thankfully can work down to 36V batteries. Here it is charging a pack  of 12S1P Headways.

Riding a C5.

This is a quick ride on the streets. It runs well apart from a squeaky brake. That goes away after a while.

C5 final touches.

I applied the finishing touches to C5 #1.

Replaced front wheel with steel hub / aluminium rim wheel from council clean-up.

 New 55Ah Battery fits perfectly. You can see the original connector has been replaced with a modern Anderson plug.

Land Rover indicators fitted. A perfect fit. Almost identical. The part number is PRC7044  They are available from eBay

C5 #1 more or less finished.

I didn't have time on the weekend to make a test ride video, but here are a few poorly lit photos.

I got #1 going by pinching parts from #2. #2 will probably never go again due to a worn gearbox output pulley and a rough body. Hopefully #3 has enough parts to make another good one.

When you ride it there will be a few things to watch out for from a maintenance perspective. The rear wheel bolt and bearings in particular. 

The side stickers are a little knocked, but look OK.

#2 looks a bit sad now. For #1 I took the headlight lens & Instrument pod.

I replaced the front wheel with a steel / aluminium one from a kids bike from a council clean up, The original one was melted. I must take a picture of that.

#1 pictures. All nice and clean. Complete with new decals where needed. It still needs a front indicator lens. I am awaiting a Land Rover indicator pair. They should be almost identical. Fingers crossed.

After test riding last weekend the drive wheel bolt was loose and the brake wheel bearing loose. I will take it on a longer run (with tools in hand) for a final shake down.

I have received some old 55Ah UPS batteries for them. The first one I tried died after a few hundred meters. The second one is holding up well. As we didn't have any battery tops, the battery power is now provided by Anderson connectors and new 6mm^2 cable.

Powerglide for an electric vehicle

Notes:
DC conversion and Powerglide http://www.poormansev.com/id29.html

Picture by picture rebuild http://www.diyelectriccar.com/forums/showthread.php/building-ev-powerglide-transmission-77105.html Pump inlent on page 8

Dos and Donts http://www.diyelectriccar.com/forums/showthread.php/powerglide-secrets-evers-should-know-22045p6.html

Boat hydraulic pump can be used for 0RPM pressure pump like those used for lifting outboards and stern drives.

Lots of good info
http://www.diyelectriccar.com/forums/showthread.php/powerglide-secrets-evers-should-know-22045.html

Direct Drive Couplers are availabe

The inside of the planetary gearbox

C5 drive components

Planetary gearbox output drive pulley:
- Diameter ~31mm
- 21 tooth

Axle Drive pulley:
- Diameter ~107mm
- 68 tooth
- One Way Bearing INA HFL 2026 Only $14.95. http://www.vxb.com/page/bearings/PROD/Kit8242

Drive Belt:
- Length = 400mm
- Width = 18mm
- Teeth = 80 tooth
- 5mm Pitch
- Megadyne Isoran 400 RPP5 http://www.megadyne.co.uk/files/Products%20Guide%20Catalog.pdf P22
- Locally - 400-T5 80 400.0 from http://www.naismith.com.au/catalogues/pulleys/metric.pdf

Final ratio = 21/68 = .308 or a 3.23 reduction.

Replacement Aluminium Pulleys from Naismith:
- Large = 60-T5-16
- Small = 20-T5-16F for similar final drive ratio.

Could use 25mm wide pulleys to allow for machining.

Motor Bearing - Both Ends: GMN 6201 http://www.gmnbt.com/deep-groove-bearings-selection-guide.htm
Planetary support bearing x2 (on drive end of motor shaft) GMN 607
Large output shaft bearing 61808

3 x Gearbox planet carrier shafts ~ 8mm

Bearings verified fron C5 yahoo group.
> > Hi Folks...
> >
> > Somewhere someone prolly needs this info..
> > Universal part numbers for the motor bearings.....
> >
> > Outer gearbox bearing: 61808 (I'd recommend a 61808-2RS cos it's
> sealed)
> >
> > Planetary carrier inner bearings: 607 (no need to worry about
> sealing on
> > these really)
> >
> > Armature main bearings: 6201 (once again I'd recommend the 6201-
> 2RS, though
> > Sincalir fitted the 6201-ZZ which is shielded but not sealed)..
> >
> > I've got a new set on order for my motor, and it's costin me a bit
> over 20
> > UKP for one 61808-2RS, and a pair of each 6201-2RS and 607....
> >
> > chrisc

Wire Sizing Guide

I got tired of Googleing this every time I needed it, so here is my version.

Gauge	Conductor Diameter	Conductor Diameter	Ohms per km	Maximum Current	Maximum Continuous Current	Cross Sectional Area	Will fit metric lug
Unit	Inches	mm	Ohms	Amps	Amps	mm2	mm2
0000 (4/0)	0.46	11.7	0.161	380	302	107	120
000 (3/0)	0.41	10.4	0.20	328	239	85	95
00 (2/0)	0.36	9.3	0.26	283	190	67.4	70
0 (1/0)	0.32	8.3	0.32	245	150	53.5
1	0.29	7.3	0.41	211	119	42.4	50
2	0.26	6.5	0.51	181	94	33.6	35
3	0.23	5.8	0.65	158	75	26.7
4	0.20	5.2	0.82	135	60	21.2	25
5	0.182	4.6	1.03	118	47	16.8
6	0.162	4.1	1.30	101	37	13.3	16
7	0.144	3.7	1.63	89	30	10.5
8	0.129	3.3	2.1	73	24	8.37	10
9	0.114	2.9	2.6	64	19.0	6.63
10	0.102	2.6	3.3	55	15.0	5.26	6
11	0.091	2.3	4.1	47	12.0	4.17
12	0.081	2.1	5.2	41	9.3	3.31	4
13	0.072	1.83	6.6	35	7.4	2.62
14	0.064	1.63	8.3	32	5.9	2.08	2.5
15	0.057	1.45	10.4	28	4.7	1.65
16	0.051	1.29	13.2	22	3.7	1.31	1.5
17	0.045	1.15	16.6	19	2.9	1.04
18	0.040	1.02	21	16	2.3	0.823
19	0.036	0.91	26	14	1.80	0.653
20	0.032	0.81	33	11	1.50	0.518
21	0.029	0.72	42	9	1.20	0.41
22	0.025	0.65	53	7	0.92	0.326
23	0.023	0.57	67	4.7	0.729	0.258
24	0.020	0.51	84	3.5	0.577	0.205
25	0.018	0.45	106	2.7	0.457	0.162
26	0.016	0.40	134	2.2	0.361	0.129
27	0.014	0.36	169	1.7	0.288	0.102
28	0.013	0.32	213	1.4	0.226	0.081
29	0.011	0.29	268	1.2	0.1820	0.0642
30	0.010	0.25	338	0.86	0.1420	0.0509
31	0.0089	0.23	427	0.7	0.1130	0.0404
32	0.0080	0.20	538	0.53	0.0910	0.032