Sunday, December 7, 2008

Exhaust

Put the Cabriolet up on stands. Disconnected exhaust..
Started removing the drive axles. Preparing to lift out the motor in January.

Many parts have arrived.. Battery boxes shipped last week.

Monday, October 27, 2008

Getting started

I removed the radiator hoses and disconnected the fan wire in preparation for pulling the radiator as well as disconnecting the ground from the battery.

Friday, October 17, 2008

Water Pump

Some EV parts have arrived:
  • The Instruction booklet arrived in September
  • 10/8: Impulse 9 motor from Warfield Electric Company
  • 10/13: The Curtis 1231C controller
  • Today: High Voltage cable (45 ft.)

The weather here in Virginia has been great for riding in a convertible, but for the last couple of weeks the Cabriolet has been just sitting idle. My wife noticed a large puddle under it one day and on further investigation it appears to leaking around the shaft on the water pump. It's probably too much for a "Stop Leak" repair, so I'll take it as the "Drain coolant" step is already completed for the ICE removal. Well maybe not completely. I want to warm the engine up at least one more time so I can get a good compression test and have those numbers available to a prospective ICE buyer.

Friday, August 29, 2008

Not Much New

Not much happening with the conversion process. The Cabriolet has been resting calmly in the garage though we take it out on the weekends for errands. I'll probably drive it into work (about a 70 mile round trip) several times next month so I can use up its last tank of gasoline.

I've received an invoice number from ElectroAuto with an itemized list of the VoltsRabbit components that should be shipping. The conversion instruction manual is the first item that will be arriving.

Thursday, August 21, 2008

Summer Day


Driving around the neighborhood on a nice summer day. The car is a little hard to start when cold which I think is pretty common problem for the CIS fuel injected VW's. My family had a '79 Rabbit many years ago and I recall it had the same trouble. My father and I replaced a couple of cold start valves. I'll check that the cold start injector is spraying when grounded and try some of the hints from this blog and see what I can do without spending any money on the ICE. Once going it drives pretty well though needs a few items to make it more comfortable. It needs one of those shift linkage kits as it's hard to find some of the gears. There is a rattle coming from the back of the car when traversing a bump, probably a shock mount. Only one speaker is working and its still needs a good interior an exterior cleaning. Anybody have any hints on what would work well to clean the top?

I'm waiting on my order confirmation from ElectroAuto and searching around on Craigslist and Ebay for tools and other items that are needed for the conversion.

Friday, August 8, 2008

Parts On Order

I sent off for the VoltsRabbit kit from Electro Automotive today. They are saying about a 8-10 week wait to get everything but some parts should start rolling in a few weeks. The journey begins..

I saw a link to this report on the BBC news today. This Chatham House report is projecting a serious oil supply crunch in the next 5-10 years that could push the price of oil to $200/barrel.

Friday, August 1, 2008

Legal to Drive

It's legal, but still under gas power. I took it to the shop this week to get a few items done one was the state safety inspection. Sort of surprised me it passed as I can't get the heater controls to blow on defrost and the ride is pretty bouncy indicating the struts are shot.

Two of the original tires had some steel showing so I had the shop install a set of the low rolling resistance Sumitomo HTR 200's. Hopefully they will give some good gas mileage while while making up my mind an ordering EV parts. Bought these at Tire Rack, I've used them in the past and I've had no trouble finding local installers. I did not replace the wheels with anything fancy. I shopped around a little and looked on my local Craigslist, but in the end I think am going to just sand and repaint the centercaps and hopefully find a couple more trim rings for the right side.

I installed some 1/4 x 1/2 bolts through the back of the licence plate holder and installed a nut then placed the plate on top and found these chrome acorn nuts to finish it. So these should come off easily when it is time to replace these plates with personalized 'electric' plates when it's finally converted.

The upholstery is in good shape (no rips or tears) just very dirty.

I've talked with ElectroAuto a few times in the last month and they are indicating about a 10 week waiting time on the VoltsRabbit kit. They do want to know what batteries I will be using so they can customize the charger. Most chargers (Russco, Zivan, etc.) will work though ElectoAuto said a Manzanita is back ordered and will be a longer wait time. But the dual voltage (110v/220v) charging would be a nice feature. I'm probably going with the tried and true Trojan T-125 or the US-125XC batteries. I called a couple of places here regarding the US-125XC but they didn't carry them.

Friday, June 20, 2008

Lights, Brakes, Plates

Well last weekend our family got the garage cleaned out and parked the VW in it while we fix a few items needed before taking it to the safety inspection station. The first item was the side marker lights. Some one snipped the wires to the back ones. I still have the bulb sockets but the bulbs fit very loosely in them and I imagine this is why the wires were snipped. It turns out there is some exemption that if the marker has a bulb and wires it has to function. But you can disable it and use it as a reflector and pass the state inspection. I could just let it go as is but I'd feel better knowing the car is more visible from the side and it will look more complete with functioning lights.

I stopped in a VW shop in my area and though they did not have any rotting Cabriolets, they did have several scrap Vanagons and the marker lights and bulb holder appear to be compatible. The Vanagon bulb holder had a flat pin connector so I just crimped on some ends.


You'd thing removing a license plate would be a pretty easy task. I did anyway, but as you can see the rear license plate was held on with self-locking nuts and two of them were turning quite freely with nothing to hold on to from the back side. So based on a really good hint in the VWVortex forums, I removed the rear license bracket holder and hacksawed the bolts so I could free the old plate and make room for my new ones. I'll need to think of a clever method of fixing that.

Lastly, I put new brake shoes on the back, I will eventually be updating the rear and front brakes once the car gets loaded with over a half ton of lead batteries. There is a store on Ebay selling a big brake upgrade for this model it replaces the stock 180mm drum with a 200mm drum from a Rabbit Pickup. Everything else is compatible including the E-brake cables.

Wednesday, June 11, 2008

High Bidder

Rest Stop
I won the bid on Sunday and my friend Ellis and I picked it up today. Very smooth ebay transaction. The car was in great condition for an 1989 model. The seller said she was the third owner. Should be a lot of fun driving once I finish a few repairs and get a new state inspection.. My kids are already bickering about which side they get to sit on.

Friday, June 6, 2008

Maybe Found One





I am still shopping for a donor car. This one looks promising, it's about 250 miles away in Harrisonburg, VA. I'm still the high bidder on ebay though the auction doesn't end until Sunday. Needs some tires and brake work to pass the VA state inspection. Personally, I think it needs some cool rims to go with those tires. If I win I plan on driving it around with the ICE and the top down while figuring out the best conversion method. I left a message with Electro Automotive asking about the wait time on a VoltsRabbit kit. Their phone greeting said it could take a while to get response due to the increased number of inquiries now that gasoline has gotten so expensive.

Another option I am thinking about is attending one of the mini-workshops run by Ampmobile Conversions. If I could be the donor car.. Wow that would be sweet to have the conversion completed in 4 days! Not to mention saving all the fossil fuels that are needed to ship a VoltsRabbit kit all the way across the US. Oh well I haven't even one the bid on this one yet. Talk about counting chickens before they are hatched!