No pistons, no fuel, no worries! Toyota Sera EV Conversion begins…

[greywolf]

Ohhhhh snap ! *Literally*

At least you didn't have to put it into the shop !

[VA61DETT]

Yer man, Do it myself, the right way!

(i hope)

-A

[greywolf]

Well if you haven't at least you'll know sooner rather than later *not quite sure why that would be a comfort *

[VA61DETT]

Allrighty,

Well there’s yer problem….

Finally got the gearbox all cleared up now, all new gear set & clutch = all good!

Currently waiting on a new CO2 cylinder as have had it with the gasless wire…

The battery box has been coming along well, fans are installed, spacer bars & retainer brackets are more-or less complete. A few more bits & I should be able to paint it up, ready for installation!
Fans Installed in base


Attaching fans


Battery spacer bars


The spacer bars are notched out at regular intervals to provide additional airflow around the base of the box, as well as support the cells over the fan holes.

Additional to this is a set of angle frame components which bolt on-top of the cells with rubber seal material which keeps everything nice and secure. (pics coming soon)

-A

[TERRA Operative]

Slightly OT, Where did you get your gearsets and how did you order them? Did you head to Toyota armed with a long list of part numbers?

[VA61DETT]

-Terra operative,

Nah,was kindof off-topic, that was one of the rooted cogs out of my mazda UTE which shat itself & caused much profanities and delays....

-A

[TERRA Operative]

I was the one OT , I'm going to be rebuilding my gearbox soon. I'm just casing out where to get parts easiest.

[greywolf]

Also interested if you obtained the gear sets through the manufacturer or aftermarket sources
.

[VA61DETT]

Righty O,

I did some ringing around and found my local gearbox shop in midland had a bunch of LOW k's import boxes which came out of ford vans.
The guy I spoke with was quite helpful, so I ended up bringing down my stuffed bits to make sure they were compatible (2 different models 28 / 24 spines).
I was fortunate as the particular 4wd box I have was worth about 2K from a wrecker or about $1700 as an exchange repair jobby.
They helped me remove the ‘welded on’ gear set from the main shaft & gave me the rundown on how to replace the gears, was pretty much a case of pulling all the gears off my box, drop kicking them, & putting on all the ‘new’ gears / bearings onto my main shaft (as the 4wd versions had a shorter shaft with a coupling for the transfer case).

Had quite a but of fun pulling everything off & getting it back together (without a service manual), took about 200 photos of every little bit going off and back on.
But in the end it worked out at about 1/3 the price of a refurb box, works like a charm now.
Quite pleased as it was my first ever gearbox rebuild

[greywolf]

That's quite impressive dude, the way you were talking about it sounded like this was all old hat to you !

[VA61DETT]

Righty,

1 small step forward…

Completed the ACC drive / Mount plate!
The A/C and power steering are both running off a single belt, with tension provided by the lower P/S pump bracket.
Everything is in more-or-less the same place, so no need to make up new hoses.

Coming together nicely!



Just need to install the main pulley & pickup a suitable size belt, should probably replace / make solid engine mounts too…. maybe later.

-A

[Jaemus]

stunning! looking forward to more

[MWP]

Hmmm... so when your at a stand-still or moving slowly the powersteering wont work?
If thats the case, it would be easier to run without it.

Quite a few people cap off the racks in EP82/91's (same rack as you would have) with no problems.

[cambelt]

Get a electric P/S pump , I know its been said but driving the A/C and P/S seems like a waste of energy or at least going in a circle with the P/S .
Dave

[Moppitt]

Although it would be worth thinking about the energy usage of any (electric) power steering pump.

What kind of drag is there on the p/s pump when not under load (wheels straight ahead and not being turned)?