Bunky the eBug: A 30 Day EV Conversion

[Gregski]

progress not perfection (yet I still used the E6071U welding rod made out of Unicorn dust and a sleeve made out of rare unobtanium)

using only Internet Approved CV Axles Grease aka IACVAG

left is in

and right is in

and bothties

[Gregski]

you must mix and match only these two types of gearbox transmission syrup

Fun Level: 2

[Gregski]

[Gregski]

next it was time to think outside the sBox, and trying to be symmetrical bit me in the butt right off the bat, can you spot the mistake in the first pic

a few F bombs later, we made the correction

I want to say check out these Gregnutz but I better not

checking for hole alignage

[Gregski]

bracket time, and we keep things simple around these them parts

and we tried her on for size

[Gregski]

cable guy.jpg (34.4 KiB) Viewed 454 times

decided to simplify things and eliminate some of the stock connections

adding the 15' extension to run back the length of the car through the transmission tunnel

negative battery to inverter cable

[Gregski]

doing a trial fit to the sBox

[Gregski]

Wait, what? These clips can go on either way ?!

back-to-the-drawing-board.jpg (59.2 KiB) Viewed 452 times

[Gregski]

well I was sort of pot committed, so I went ahead and made the positive battery cable extension as well

this thing has black wire loom in the middle because that will be hidden in the transmission tunnel and I didn't have enough orange stuff

[Gregski]

yes the stock positive cable is slightly longer, YES, that will drive me nutz!

[Gregski]

nothing to see here, just fishin' the battery cables through the trans tunnel

ever wonder what to do with the remaining 10 feet of welding wire when you ran out and the welding machine can't push it through

not a fan of this high voltage battery cable routing at all, must think on it

[Gregski]

so ended up making another positive cable so that it's the same length as it's negative buddy

[Ghia66]

Knew you would!!!

[Alibro]

I didn't think that would stand the Greg test!

[Gregski]

slightly revised schedule for the purpose of steadfast driveability with some built in padding for nice to have little things like: brakes and seats which I will do off camera on this forum anyway, the Flintstone floors will be delt with later... much later

[Alibro]

slightly revised schedule for the purpose of steadfast driveability with some built in padding for nice to have little things like: brakes and seats which I will do off camera on this forum anyway, the Flintstone floors will be delt with later... much later


Revised Bug Build Schedule.jpg

You don't need to count rot repair in the 30 days. We are kind and helpful that way and are only holding you to the EV conversion.

[Gregski]

You don't need to count rot repair in the 30 days. We are kind and helpful that way and are only holding you to the EV conversion.

Bummer !!!

[Gregski]

the pedal SITUATION was next, I had to use an excavator to get the pedal assembly out

First we had to divorce the clutch pedal, which was easy enuff

then we had to delete the mechanical skinny pedal

leaving us with this fugly thing

nothing a little tickle with the angle grinder couldn't solve

and normally we would paint it black and put it back, but we was all out of paint

[Alibro]

Are you going to replace the floors or just put extra stiff carpet down?

[Gregski]

Are you going to replace the floors or just put extra stiff carpet down?

will buy four new quarters and cut them down to what I need once the car drives, the floor pan bolts up to the body so I only need to weld 3 sides of each panel

[Gregski]

next it was time to mountenize the Honda Fit drive by wire hall effect throttle pedal

so that's the general idea, simple

[Gregski]

then it was time transfer the shape to metal using my freestyle CNC machines


we only use the finest pieces of scrap metal here at the Good Enuff Garage

love these hole center pokers

needed to make one bolt a stud instead for clearance issues

hold it righty there little buddy

[Gregski]

tacked into place

[Gregski]

and bugger welded in, I could not get my big head under that steering wheel with the welding helmet on to see what the hell I was doing, so I welded blind

looks like folks in the back seat will have no problems reaching this throttle pedal

[MattsAwesomeStuff]

the pedal SITUATION was next, I had to use an excavator to get the pedal assembly out

Okay so it's not just me. I had a hell of a time and eventually just gave up.

I could not get my big head under that steering wheel with the welding helmet on to see what the hell I was doing, so I welded blind

Again, just watching the camera angles I was thinking "How did you even get your head in there?"

I remember when I was trying to reach the pedals, the steering wheel blocked my shoulder, the turning indicator was in my ear, and I could only reach them with the tip of a long screwdriver.

I later took the seat out and still couldn't reach anything worth a damn.

That point where you're panting and struggling and cramping and sore and need a break, and you haven't even done anything other than try to reach where the work should be happening.

...

Congrats on first wheelspin. You hit that without much fanfare. I've taken 5 years to get to that point sometimes. You're barely 5 weeks.