Holey rusted metal, batman

...is what you find on steel parts of a car which has been used in Scotland during the winter. Because we like to put as much salt on the road as we do on our chips.

Even though you might expect a bit of cathodic protection of the steel, this bit was badly corroded and fit to fall off.

Anyway never mind, we can happily remove all that because it was only holding on some vapour emission control stuff.

A required hole also appeared, as predicted:

There is pleasingly very little in the way and a nice big rectangular battery box will fit snugly here between substantial crossmembers. The car will end up with much more rear load space than it had as a hybrid.

Of course it's important to remember that it's always easier to dismantle than it is to create, and the next step is going to involve some creative aluminium origami, so stay tuned for that riveting fun.

Day one

I've finally decided it's time for a new electric car project. The last homebrew one I had was back in '99, and the recent rate of progress with technology and batteries means it will soon be pointless to build your own (I mean, it technologically is already pointless now that the Tesla model S exists, but I can't really afford one of those).

So I'm converting a Mk 1 Honda Insight. It will get a 100kW drive, which should give the light and aerodynamic donor vehicle new wings, and make my new, longer commute a bit more bearable than in my 55mph top speed Peugeot 106 electric.

First of all, the poor car had been sitting idle for a few years, and the drum brakes had *completely* seized. It took some effort and a set of bearing pullers to get the drums loose (dragging the car and hammering on the drums having failed). Drumroll...

Next, the huge and complicated IMA package (including NiMH battery) came out.  About 100 fasteners had to come out first though. It's proper quality engineering this, a beautiful job for what was a rather limited production run.

It's pretty heavy, 50kG at a guess.

With this and the fuel tank removed, there is a promising battery shaped cavity between the beam axle and the back of the floor pan.  I will remove the glued and spot welded "hump" and sink a battery box in here, to hold about 100 of these little guys:

The intention is to keep the batteries in a single block behind the seats. This will make thermal management as well as electrical considerations easier.  The weight will be as far forward as possible, inboard and low down for reduced roll and a small polar moment of inertia, and the spare wheel and tools etc can move to under the hood, to restore balance.

That's about it for today. Plug in for more!