DIY Electric Cars!

Posted on November 7th, 2007 in Driving Emotion,Economy,Hybrid Power,Opinion,Technologies by Julian Edgar

electric-charade.jpgLast weekend I attended an electric car show. Organised by the Sydney branch of the Australian Electric Vehicle Association, it was unlike any other car show I’ve ever been to.

Why?

Well, firstly, the cars were different to 99 per cent of vehicles on the road. With the exception of a few current model Prius Toyotas, they were all home-converted battery electric vehicles. That’s right, (mostly) road-registered and street driven, these cars never visited petrol stations but instead needed only to be plugged into mains power.

Another thing rather different about the show was the interest being shown by visitors.

At a typical car sow you’ll get lots of lookers but few talkers. Here, every visitor had dozens of questions – and some even came equipped with notebooks and were writing down the answers. One guy had come all the way from Canberra and was actively seeking the information to enable him to have a car converted to electric power for his daily commute.

Others were asking about conversion costs, battery life, range, performance – and everything else you could imagine.

There was a constant buzz of interested conversation.

Along with the road-registered cars, there was also an electric kart, a half-built electric clubman and an electric motorbike. The road vehicles included a Camry wagon, Daihatsu Charade, Hyundai Excel, Daewoo Lanos and even a Mazda ute.

I was attending the show to gather material for some AutoSpeed stories, and got to drive three of the cars. We’ll be running these stories in due course, but in the mean time, if you’re at all interested in building your own battery electric car – or having a car converted to battery electric power – be aware that there’s a bunch of very enthusiastic and helpful people available to you as a resource.

Ride quality…

Posted on October 23rd, 2007 in Driving Emotion,Opinion,Suspension by Julian Edgar

cobb-and-co.jpgI have never been for a ride in a stage coach but it’s something I’d very much like to do. And preferably at full speed, the team of horses at a gallop. Why? Well, primarily because I wonder how well the coaches ride.

I have a book on Cobb & Co, the best known and largest of the stagecoach companies in Australia’s history, and the map showing the routes that the coaches took is stunning. Especially in Queensland, they penetrated way into the inland – true Outback territory. The roads – always dirt and often largely unmade – were terrible and yet the point to point times were actually quite quick. (The coaches ran to timetables like buses do today.)

The coaches used long-travel (and large!) elliptical leaf springs – sometimes transverse as well as longitudinal – and had huge wheels. AFAIK, damping was provided only by the inter-leaf friction of the springs – no dampers were fitted.  In short, the suspension design was as far away from contemporary small wheel, short travel, highly damped suspensions as possible.

But I have a suspicion that these vehicles might have had a very good ride indeed. The large wheels simply wouldn’t have noticed the bumps that a modern car’s wheel would crash into; the very long suspension travel and low natural frequency (at a guess the static deflection would give a resonant frequency near to 1Hz) is close to ideal for human comfort.

A horse-drawn stage coach riding better than a current car? I wonder…

A Tyre Trap

Posted on October 9th, 2007 in Driving Emotion,Tyres by Julian Edgar

michelin_pilot_sport.gifIt’s an obvious thing, but not so obvious that I haven’t been caught twice in the last month. When buying a secondhand car, or just the secondhand tyres off a car, check every tyre!

To the latter first. Recently someone in the small town in which I live advertised the tyres from an EF Falcon. ‘Near new’ said the ad. Since at that time I still owned an EF Falcon, I rang up. The seller didn’t know the tyre size but dutifully went away and checked. The size was right, so I went off to inspect the tyres.

Much to my surprise, I found that the tyres – and wheels – were still on the car! A wagon, it had spun and hit a tree. The car was a write-off, but the owner was trying to recoup more than she’d have got from a wrecker. So, the tyres (and wheels) were for sale, as was the engine. Trouble is, she didn’t tell anyone that you’d have to get them off (the wheels) or out (the engine) on your own!

This flummoxed me a little, especially when I pointed out that if I took the wheels and tyres off the car, it’d be awfully hard to move around her steep, grassy backyard – that’s where the car was. So, I suggested, perhaps she should place the car where it would be easy to winch, wheel-less, onto a truck when it was time for the car to finally go. I looked at a couple of the tyres, saw the brand-new tread, and made an offer. She accepted, so I went off for my trolley jack.

It was only when I was taking off the wheels that I noticed that in fact only two tyres were near-new. The other pair was probably half worn. But it was too late to complain… I should have checked the tyres more carefully before making my offer…

And blow me down if the same thing didn’t nearly happen again! This time I was buying a complete car. With the incident of the Falcon tyres still very clear in my mind, I checked with more than usual care the tyres on the car I was buying – a Peugeot 405 SRDT. And, again, there was a surprise in store.

Incredibly, the sizes front and back didn’t match. Now that might not be a shock on a Porsche 911 but it certainly is on a Peugeot 405! The correct standard tyre size for the Pug is 185/65 14. But lo and behold, on the back were 185/70 tyres! I quizzed the owner and he waved away the problem with a sweep of his hand. But why were they different? Oh, he said indifferently, perhaps his son had been responsible for getting those put on the car…

So, as I said, always check all four tyres….

Cuts and abrasions…

Posted on October 4th, 2007 in Opinion,Safety by Julian Edgar

dettol.jpgThose of us who are not full-time workers on cars, but instead are enthusiasts who don’t get their hands dirty on a daily basis, are most likely to benefit from this product.

So what is it? It’s an antiseptic liquid that you dispense from a pump-pack and then wipe over your hands. The stuff dries quickly and doesn’t leave a sticky residue.

I find it particularly effective when I cut my hands (looking now I can count six minor cuts, three of which are open) as very often heavy duty hand cleaners have the unfortunate side-effect of infecting cuts.

So you’re working on brakes or an engine or bodywork and, at the time you inflict a minor cut on yourself, your hands are filthy. If the cut or abrasion is of little consequence, you leave it and then later clean your hands with a heavy duty soap or dedicated hand cleaner.

And if that’s all you do, it’s likely the open wounds will get infected.

But if after cleaning your hands, you give them a wipe-over with Dettol Instant Hand Sanitizer, the later infection is avoided.

There may well be other products that work in the same way – it’s just that I haven’t come across them. For minor cuts and abrasions it’s much better than the antiseptic cream you might apply to a more serious wound – you can quickly and easily spread the sanitizer over both hands by just squeezing some of the liquid onto a palm and then rubbing your hands together. It doesn’t need to be wiped off – it then evaporates.

The product costs $5 or $6 and it’s available at supermarkets.  Note that it’s highly inflammable, so use it on your hands only after you’ve left the workshop…

(And no the sample wasn’t a freebie – I bought it just like anyone else.)

Turbo tech developments…

Posted on September 28th, 2007 in Opinion,Turbocharging by Julian Edgar

speed-sensor-1.jpgBorgWarner Turbo & Emissions Systems has developed a new turbo speed sensor.

The eddy-current design is mounted on the compressor housing, with the end of the probe flush with the inside of the compressor cover. Designed to measure turbo rotational speeds from about 1000 rpm to 350,000 rpm, the sensor is non-contact and so wear-free.

A smart sensor that takes a 5-volt supply and includes internal electronics, the sensor body can withstand 180 degrees C and the exposed tip up to 250 degrees C. The sensor has a service life of 1.6 million kilometres.

BorgWarner suggest that a primary use of the sensor is in providing over-speed protection but the regulation of turbo speed by a feedback loop is another obvious application. As an input into the engine management system, along with temperature and ambient pressure, turbo speed measurement would allow the turbo to be run much closer to the surge line without danger. Bigger compressors and smaller turbines, allowing better low-down boost, would be the result.

Along with electric assist turbos the future of turbocharging looks bright.

One reason I don’t think much of the Type R Civic…

Posted on September 24th, 2007 in Handling,Honda,Opinion,Power,Turbocharging by Julian Edgar

type-r-on-dyno.jpgToday I returned Honda’s Type R Civic to the Queensland office. I am quite happy to see it go: I think the Civic Type R is a pretty weak car – something I make clear in our road test that will appear in AutoSpeed in due course.

With a 2 litre naturally aspirated engine that revs to 8000 rpm and develops 148kW, it might look the goods on paper – but the reality is very different.

To go further, I think the idea that small, naturally aspirated engines can compete with turbo cars is the stuff of fairytales.

The Peugeot 206 GTi 180  and Ford Focus ST170 were similar cars in concept to the Type R Honda – all based around the idea that naturally aspirated, high revving engines have some intrinsic advantage over their forced induction competitors. That’s a purported advantage over turbo competitors that have more peak power – and vastly more average power through the rev range.

High speed wire brushes…

Posted on September 19th, 2007 in Driving Emotion,Technologies by Julian Edgar

twisted-wire-brush.jpgMaybe everyone already knows about these – but I didn’t and since I have discovered them, they’ve been extremely useful.

What I’m referring to are twisted wire brushes designed to screw onto angle grinders. You take off the grinding disc (and then leave off the screw collar – don’t lose it!) and then screw the wire brush onto the shaft.

The angle grinder spins the brush so fast that the amount of material you can quickly remove is amazing. Compared with a wire brush you might use in an electric drill, you have much better control (using two hands rather than one) and can achieve results perhaps 20 times as fast.

For example, today I needed to clean up the exterior of a big muffler. It’s stainless steel but of the sort that slowly rusts. There was corrosion all over it and I wanted a clean surface to paint. Literally 5 minutes of work with the angle grinder-driven wire brush had it looking so good I even considered not painting it! (But I did anyway.)

However, when using the brushes, you must wear full protection – goggles, ear-muffs and good clothing. The brushes tend to shed wires and at the speed they’re travelling, they could do eyes very serious damage. In fact, if you have a clear full length face mask, I’d suggest using that.

When buying, take along your angle grinder (with disc removed) so that you can be sure of getting the right thread size. The twisted wire brushes are available at hardware stores and tool suppliers.

Real racers…

Posted on September 17th, 2007 in Aerodynamics,Driving Emotion,Technologies by Julian Edgar

hpv-racer-2.jpgI spent last weekend at Maryborough in Queensland. So what was happening in this pretty town, a little inland from Fraser Island? The Holden-sponsored Maryborough Technology Challenge (MTC), that’s what!  

The MTC consists of technical competitions designed for school students, both primary and secondary. The challenges – that are really races – are fun and pedagogically worthy. Amongst other events, they consist of pushcart races, solar-powered boat races, robotics challenges, CO2-powered miniature drag racing and a human-powered vehicle race.

boats.jpgI went along primarily to watch the human-powered race but found myself much enjoying the solar-powered boats. The boats race side by side in pairs, pushing their way through a long shallow pool. They are kept in line by wire guides following two stretched longitudinal fishing lines.

The differences in boat performance were extraordinary – some boats just plugged along while others lifted their polystyrene noses and powered through the water, leaving a substantial wake. One student that I quizzed told me the electric motor driving his craft was Swiss-made – it was about as big as an AA cell yet gave the boat amazing performance. And of course, all the boats were directly powered by the solar cells mounted on them. As a way of integrating into the curriculum concepts of hydrodynamics, solar cell and motor efficiency, propeller pitch, renewable energy (and of course team-work and co-operation), I thought the boats were fantastic.

Left foot braking

Posted on September 14th, 2007 in Handling,Opinion,Safety,Suspension,Tyres by Julian Edgar

brake.jpgWhen you were taught to drive I’d wager 10:1 that no-one ever said anything about left-foot braking. The left foot was for the clutch, or in an auto car, for bracing yourself when cornering. (The driving instructor never said anything about that either? Oh well.)

I first started left-foot braking about 15 years ago. After reading a story on RWD handling that described left-foot braking, I decided to have a go. The first thing that I found was that after years of accelerator operation, my right foot had developed a super sensitivity – but my left foot was used to only operating the clutch. Left foot braking therefore resulted in a crick in the neck, until I learnt some sensitivity with that foot as well!

The worth was proved when I found myself pedalling a loan car, one that handled like it was shod with 75 series rubber pumped up to 20 psi.  The auto car had chronic understeer, but – much to my surprise – I found that it could be largely cancelled-out with a dab or two of left foot braking.

When the throttle jams…

Posted on August 30th, 2007 in Opinion,Safety by Julian Edgar

skidmarks.jpgHaving the throttle jam fully open is a pretty exciting idea. And an even more exciting reality.

I’ve had the throttle jam fully open twice in my driving career.  Once it was in city traffic, in second gear.  I’d just had the throttle body-to-plenum rubber hose off, and when I’d replaced it I hadn’t orientated the hose clamps the right way around.  The result was that when the throttle lever moved past the clamp screw it couldn’t get back: instant sustained Wide Open Throttle. 

After thinking “Shit!” I turned off the ignition key and then swapped lanes to the curb.