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