Rear mounting bracket

[Hondacrzy]

Hi everyone

Is anyone planning on keeping the a/c system and are they running off
the tail shaft of the motor? My plan is to keep the lower front engine
mount, which is also the compressor bracket. I have been playing
around with E-Machine shops cad software but until I get the motor
installed I am not sure of the measurments or if there will be room.

Thanks Chris

[Rob Connelly]

Hi Chris,

I kept the A/C in my '95 Civic DX, and I do run it off of the tail shaft of
the motor. It works great. I do suggest that you keep the clutch with that
approach, since the compressor load makes motor synchronization with the
transmission more difficult. I elected not to keep the compressor/torque
snubber bracket in my installation. With the electric motor not having as
much rotational inertia (and vibration) as the ICE, I don't think that
snubber is as important. I did keep all the other factory mount points,
however. See the attached photos. I designed a bracket that serves as the
motor mounting plate and the compressor/idler pulley mount. I used the
original idler and motor pulley. I do have most of this in CAD -- and
not-100%-professionally-detailed drawings for a machine shop -- if you would
like to use this same approach.

- Rob

[Monkey EV]

Rob,
I would be extremely grateful for any Cad files or drawings of your
system. It looks quite nice.

Eric D.

On May 14, 6:29 am, "Rob Connelly" <r...@finelineprototyping.com>
wrote:

[Rob Connelly]

Sure thing, Eric. And I have all the solid models that I made to create
this, but they are in Alibre CAD format. If someone can tell me what format
could be imported into Google Sketchup I would be happy to export from
Alibre and provide this to the group. The motor is modeled as well -- a
Netgain Impulse 9 with tail shaft.

A few comments about the design:

1. The Pulley Bushing slips over the tail shaft, and acts as the adapter to
allow the original pulley to be slipped on with a key (the key will have to
be modified slightly to fit the pulley, but your machine shop can do that
very easily.)
2. The pulley then slides on, and the Pulley Cap goes on to trap it against
the bearing face of the Pulley Bushing. A 1/4-20 bolt with some Loctite can
then hold it secure.
3. Notice in the photographs that I used hex standoffs to position the
idler bracket and compressor away from the mounting plates by the proper
distance. I can get you ballpark heights for those, but you should use them
as ballparks anyway -- make sure that your hardware all lines up well before
bolting/welding them in place. I welded one end of each standoff to the
plate, and used the other to accept the mounting bolts. The standoffs are
not modeled in CAD -- notice that the components are floating in space. I
made them to fit on site. (Eli Whitney would not be proud of me for that, I
know.)

This does in fact work, at least for 120 miles or so (the amount that I have
on my Civic in EV mode at this point.) I have been on the interstate at
65mph with the A/C blowing full!

- Rob
----- Original Message -----
From: "Monkey EV" <eric.d...@gmail.com>
To: "Civic EV Kit" <civic-...@googlegroups.com>

[Hondacrzy]

Hey Rob

All I can say is NICE!!!! That is very similar to the ideas I had
scetched up, but I had not got that far. Is your civic complete and
can you share what you are using for other components in your build.
(batteries, controler, battery box ideas, guages). Thanks again for
the very nice info.

Chris

[Rob Connelly]

Chris,

Thanks for the nice compliment! It has been a fun project. And yes, it is
complete now -- at least I am driving it in my daily commute -- but I expect
I will be tinkering with it for years to come adding new features and such.

I used 12 Optima 31's for batteries, making a 144V system. I used the
entire suite of components from Belktronix (www.belktronix.com) and I must
say that I am pretty impressed with it. It was designed for AGM batteries
like the Optimas, and has everything you need. I have a Gast vacuum pump
for the brakes. I did not use any battery boxes since these are sealed
batteries, and Optima tells me they can take the heat/cold of my climate
here in North Carolina. Guages are something that I will develop further
hopefully with a computer-controlled approach and display, but that is going
slowly. For now I run with a Xantrex XBM e-meter, and Belktronix sells a
prescaler so that it works with the 144V system. The only issue I have with
the XBM is that the heat inside the car on even a mildly sunny day in May
can make the display unreadable until it cools. I can only imagine what it
will do in August here.

That's it in a nutshell. I'll put photos of the complete job on the web
eventually, but I am on the hook to build a treehouse for my two boys first,
now that I am driving this.

- Rob
----- Original Message -----
From: "Hondacrzy" <Hond...@msn.com>
To: "Civic EV Kit" <civic-...@googlegroups.com>

Sent: Thursday, May 15, 2008 12:12 AM
Subject: [CivicEVKit] Re: Rear mounting bracket

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