Fun With Power Tools - September 2004
The basic chassis parts of the EV 3 are a VW transaxle, a modified VW front end, and a chassis from Berrien Buggy. Our prototype uses pre 1965 components. This means a Link and Kingpin front suspension and a swing axle rear suspension. Later versions can be used, you just need to know which versions you have to order the correct chassis from Berrien Buggy.
This first video shows Xander using one of his favorite tools to cut the VW transaxle away from the motorcycle "trike" that was one of the donor vehicles. Xander also talks a bit about engine removal.
Our vehicle design calls for using a standard VW transaxle, without the clutch. Some designs eliminate the transmission and simply use a fixed gear ratio. I personally believe it's important to retain the transmission in order to improve the overall operating efficiency. However, the clutch is not necessary, and in fact, might cause the motor to self-destruct! If the clutch was accidentally depressed while the motor was under full load, the motor could suddenly over-speed and exceed the maximum operating RPM. When shifting without a clutch, about the only difference you will notice is you have to shift a little slower. The transaxle shaft should be modified to allow the motor to fit closer to the transaxle. You need to cut the tip off the end of the transaxle.
The Chassis - Get It Level Then Weld - October 2004
The chassis arrived from Berrien Buggy and we could hardly wait to start our custom fabrication! In just a few short hours, we had about 90% of the chassis tack welded. I have to say the chassis was all we expected and came together perfectly. The parts were pre-cut and part of the frame was tack welded from the factory. This helped ensure the frame was perfectly aligned. However, it was still up to us to make sure the frame was level. That took a bit of effort, mostly because the rear end was not completely disassembled as suggested in the instructions and the driveway we were building on was slopped in two different directions! As you'll see in the video we managed to get it perfectly level and ready to weld!
A word of caution, it's easy to get the hang of welding... but it takes a lot of experience to be good at welding, so as a home build project, it's okay for you to tack weld everything together; but, if you're a welding novice, make sure that you take the project to a professional for the final welds!
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