August 29, 2011 by Rob.

Alex and I spent the pre-100 morning checking the circuits in the RAVolt to isolate the drive system failure.  We confirmed it was not the traction voltage, aux voltage, motor continuity, key lockout or pot box.  Sadly, that only left the Curtis 1231C controller.  We removed it and I’ll send it out to be remanufactured.

In the process, I did manage to fry one of my contactors.  Note to self: do not create a short between the battery and the motor - the contactors cannot handle the arc.  On the positive side, I’m certain Alex will never forget today’s efforts together.

Posted in Safety, Parts, Storyline | 3 Comments »

April 25, 2011 by Rob.

After some minor painting, the battery replacement for the RAVolt went off with any issues.  The alternate cells Trojan T1275 were a good fit without needed to change the terminal connector layouts.

I especially like the new lifting ears.  We made some simple lifting straps so moving the cells was much easier than using the J150’s built in handles.  I wish they were in the original design because I could have aligned the cells to make it easier to have tie downs.

I have not yet tested the range on the new cells - I expect to be back to my 30 mile range.  Trust, but verify.

Posted in Batteries, Storyline, Conversion | 5 Comments »

April 8, 2011 by Rob.

Now that the brakes are fixed!!  I took Alex for his first RAVolt drive.  With the old batteries, it takes a very careful foot.  He’s excited to have the RAVolt has his daily, so we’re getting new batteries.The current range is just about 2-4 miles (of very timid driving).It’s been 4 years since we got the first set (about this same date in 2007) and prices are up about 50%.  Each cell will cost $150 for the T1275.  If I tried to order the old J150 cells, they would be a special item and $200.The T1275 is the same weight and amp-hours.  It’s slightly shorter (13″ vs 13.75″).  That difference may come from the lack of useless lifting edges on the sides.   My big concern is the terminal posts, but those _appear_ to be the same.We’ll find out on Tuesday - that’s when the J150s go to the big smelter in the sky.  It will take a few days before I find the time for the install.BTW: My supplier is Continental Battery in Belton.   Thanks to Bill Gooch on the AustinEV list for the recommendation.

Posted in Batteries, Parts, Improvements | 4 Comments »

March 27, 2011 by Rob.

Please note: I am still ACTIVE blogging on RobHirschfeld.com.  The topics there are NOT EV related: I am posting about Agile process and Cloud Software.

Posted in Conversion | 2 Comments »

March 27, 2011 by Rob.

Last month I was able to repair the brake line.  Some acid had leaded onto the steel lines and eaten a hole in one.  Alex and I had to remove the batteries from the front and disassemble the brake line junction.  It was easy and cheap to buy a replacement line.  The replacement lines can be hand bent to route them past the leaking area.  The bigger challenge was the double flair needed to connect the cut line into the replacement section.Once I’d mastered the flair, we just had to bleed the brake lines (surprisingly easy) and replace the batteries.After that, the brakes held pressure and we were able to take a short 2 mile cruise to prove out the system.   Now that Alex has his learner’s permit, he can actually take the RAVolt out around the block.That’s about as far as we can go until I order some new batteries.  I’m planning to do that THIS WEEK.The RAVolt has been idle for over 18 months.  With $4 gas around the corner, my timing is looking very good.

Posted in Brakes, Safety, Parts, Storyline | 2 Comments »

September 28, 2010 by Rob.

On Saturday, Joe K came over to salvage my MR2 PS pump that I’d installed and never used in the RAVolt.  Joe’s working on a B2600 pickup conversion.  We hooked up through the AustinEV list, but it turns out that we have mutual friends through the Roller Derby!Removing the pump turned out to be a real pain in the ass.  It was behind the motor and locked between the axle supports.  After 2 hours of dirty work, we did manage to liberate it from the RAVolt.   I hope Joe has better luck with it than I did.

Posted in Parts | 2 Comments »

September 28, 2010 by Rob.

Kate and I had to drive an extra trip around the block to watch it flip over!

Posted in Storyline | 1 Comment »

September 22, 2010 by Rob.

The RAVolt’s been offline for an embarassingly long time - I finally too it to the shop (Broddus Chevron in Rollingwood) to get the master cylinder replaced, new pads, and lines.  I had to restring the batteries and remove corrosion before the car could move on it’s own power - that’s the subject for another post.

Props to the mechanics at the Chevron!  They were more than glad to work on a frankencar.  Frankly, I was afraid that no shop would be willing to take on a repair for such a heavily modified vehicle.

I’m looking forward to getting to drive the RAVolt around town again.  It’s been way too long.

Posted in Safety, Storyline | 1 Comment »

September 26, 2009 by Rob.

In tweaking my aux voltage, I finally blew my Astrodyne DC-DC regulator.  The poor beast had major acid damage so it was about time.

Posted in Improvements | 6 Comments »

July 9, 2009 by Rob.

The RAVolt celebrated it’s 2 year EV anniversary in the Rollingwood July 4th Parade.   For updates, check out the RAVolt on BrightKite (better pictures) or Twitter (tag #EV).

The heat is killing my batteries - down to about 15 miles of reliable range.   That is assuming that it ever gets cool enough to drive!

Posted in Daily Use, Storyline | 1 Comment »