1984 Voltswagen Rabbit Prius Gen 3 ZOMBIE

[Gregski]

VW MK1 Outlander Battery Charger Install DIY EV 2

decided to reinforce the steel by plating it before welding the charger brackets to it

[arber333]

VW MK1 Outlander Battery Charger Install DIY EV 2

Yes... i think your idea is doable.

[MattsAwesomeStuff]

VW MK1 Outlander Battery Charger Install DIY EV 2

"Hopefully not some type of pot metal"

"Pot metal" is usually referring to castings. As in, it goes into the melting pot. Generally tin, aluminum, zinc. All of which are more expensive than steel by multiple orders of magnitude. The only reason you'd use them is because you don't need exotic casting methods and refractory materials to cast them like you would iron/steel.

The cheapest thing you can make sheet or stampings out of... is already steel.

So good news, even random garbage grade angle iron is still ... steel.

I've heard that you can't rely on it, it'll have nodules of hardness scattered randomly within it, it might tear or shatter. The alloy won't be consistent, the temper won't be consistent, the weld might fail. Blah blah blah blah blah. I just consider it to be the lowest grade of steel and act accordingly. Nothing I do is engineered within ... actually none of it is engineered at all.

The local dump usually has stacks of 10-30 cheap bedframes in a pile, and I can usually grab one for a buck or two. I've been too lazy to accumulate a hundred bucks worth of a lifetime supply, but, I'll get around to it when it's battery box time.

...

I had anxiety about that square hole half covering those bolt accesses for 2/3 of your video. Muchly improved to give it clearance.

...

One upgrade I'd make, for lateral strength, is to add a, oh, 3/4" rib or two along the flat faces, kinda pointed between or running nearby the bolt holes. Even 1/8" is floopy floppy sideways. One little bit of buttressing will make it bulletproof. Probably unneeded, but a little extra effort would give me peace of mind if it was my project.

...

On the angle iron you have, you don't have to have the horizontal part covering over the inverter unless that's necessary for fitment. You could flip it so it faces away from the inverter top, like the way you carry a rubbermaid.

[Gregski]

The local dump usually has stacks of 10-30 cheap bedframes in a pile, and I can usually grab one for a buck or two. I've been too lazy to accumulate a hundred bucks worth of a lifetime supply, but, I'll get around to it when it's battery box time.

always appreciate the feedback Matt, and my take away... "for a buck or two" ? amateur, I pick mine up from the side of the road for FREE and if I'm lucky I'll brush up against some fresh poison ivy

[Gregski]

this is gonna be a game changer ...

[Gregski]

I can't believe all my friends scheduled their reverse vasectomies on the same Monday afternoon, fools, so while they're sitting there in the clinic waiting rooms I got a chance to install this transaxle

Note To Self: Patten this before the Euro Boyz steal it and call it the Soloist 8000

[Gregski]

[Gregski]

apologies for the shadows, it's what you get with a West facing garage

[Gregski]

The ZombieVerter VCU is there cause we have to plug the MG2 connector in before the driver side bracket goes on, foolish design I know, letters shall be written to the Manufacturer

[rstevens81]

this is gonna be a game changer ...

this reminds me of...

NLP.jpeg (6.42 KiB) Viewed 1332 times

greg griswold

[MattsAwesomeStuff]

this reminds me of...

Place I used to volunteer, had equipment gradually added to one of the bays. Eventually someone wondered, I can't see an outlet, where is all of this stuff even plugged into? And then did a roughly geographically correct layout sketch spanning 600 square feet of shop space.

[Gregski]

84 VW MK1 Rabbit Seat Pan Rust Repair With The Wife

[MattsAwesomeStuff]

A bead roller?

Pffft. Man I thought you were one of us. That was a job for a ball peen and a 2x4 with a groove cut into it.

Go back to your ivory tower with the other professors and chortle about caviar prices and crystal sculptures.

[Gregski]

A bead roller?

Pffft. Man I thought you were one of us. That was a job for a ball peen and a 2x4 with a groove cut into it.

Go back to your ivory tower with the other professors and chortle about caviar prices and crystal sculptures.

bwhaaa haa ha, did I mention I had an assistant !

[Alibro]

A bead roller?

Pffft. Man I thought you were one of us. That was a job for a ball peen and a 2x4 with a groove cut into it.

Go back to your ivory tower with the other professors and chortle about caviar prices and crystal sculptures.

Likewise I was expecting a grooved 2x4 and an M12 bolt with the head cut off and poorly reshaped ends resulting in the usual hammering of thumbs, heavily distorted sheet steel and a multitude of profanities.

This level of professionalism has no place here.

[arber333]

bwhaaa haa ha, did I mention I had an assistant !

And expectation led me to belive i was going to see the actual use of that damn contraption together with a chapter of english wheel and tap hammer application . Well done.

[Gregski]

And expectation led me to belive i was going to see the actual use of that damn contraption together with a chapter of english wheel and tap hammer application . Well done.

ha ha, well some Shop Secrets I will just take to the grave


so is that convex or concave now with that crown?

mandatory Stare N Compare, [the old pan is on the right ]

Anvil's are stupid expensive where I live, how about in your hood?

[Gregski]

On this episode of You're Doin' It Wrong: we join in holy matrimony the Prius inner CV axles with the Rabbit outer ones, [for test purposes]


First the driver side, note this one is now a tad longer as The Greg decided to drop the Prius transaxle more in the middle Politically Correct Centrism Style as to not offend anybody. When we have one professinaly made we may have them use a larger diameter hallow tube like the passenger side

this would have been a breeze had it not been for the typical German sense of humor as they decided way back in 1984 they would make their shafts 1 millimeter larger in diameter than those of the Japanese Toyota Prius ones, making welding them up on center a bit tricky dicky - nothing a few random feeler gauges shoved inside the tube wouldn't almost solve

so first we welded the two solid shafts together, then we ground that down, and slid the tube over the joint, and welded it up at the ends and in the pre drilled plug holes - this ought to spin the wheels with the Rabbit off the ground and give us some idea of how we did on shaft lengths

[Gregski]

this is queued up to how I hope to make it straight(ish)

[arber333]

.....
Anvil's are stupid expensive where I live, how about in your hood?

Let me tell you something... even me, i shy from replacing the whole panel at the rear seats like you just did. Kudos!
I simply took OBCs as far up as they would go and designed mounts from the underside.

But i do have an anvil amd tap hammer. Alas i dont have that dexterity that certified sheet metal repair mechanics have. My friends dad is capable to form a wheel well replacement by himself + tap hammer and anvil. He said it was mandatory lesson in his school.

[arber333]

this is queued up to how I hope to make it straight(ish)

Now that is informative! Really shows theory and pactical application. Must see if you are extending some shafts. I just luve the NDT penetrant inspection.
Some of the mechanics are shying away from this but it is really simple visual inspection and can accurately predict failure in part and even show you the rate of failure.

Can we make a wiki on driveshaft extension? This deserves to be there...
EDIT: I put the link to video on wiki with mechanical design
https://openinverter.org/wiki/Main_Page ... n_Database

[crasbe]

so is that convex or concave now with that crown?

It's Pringle shaped

[Gregski]

EVBMW.com ZombieVerter VCU First Power Up & Firmware Upgrade




List of authentic Damien Maguire's ZombieVerter Videos with some points of interest

• Jan 10, 2024 - ZombieVerter VCU Software V2.04

• May 10, 2023 - Lab Update: ZombieVerter VCU Firmware V2.0
  • VCU Ignition Start Procedure

• Feb 4, 2023 - ZombieVerter VCU Update Feb 2023

• Jun 11, 2022 - ZombieVerter VCU Part 4

• Nov 3, 2021 - ZombieVerter VCU Part 3
  • VCU Throttle Calibration procedure

• Oct 24, 2021 - ZombieVerter VCU Part 2
  • VCU Connector Pin Out
  • VCU Firmware Upgrade
  • VCU Web Interface
  • VCU Parameters
  • VCU Charger Control

• Jul 25, 2021 - ZombieVerter VCU Build Part 1
  • What is the ZombieVerter VCU?
  • Basic Power Up Test
  • Enclosure, Header, Connector & Wire Harness

[crasbe]

this is queued up to how I hope to make it straight(ish)

[evbuilder]

I've found something odd in the code I think you are using: (this? https://github.com/damienmaguire/Stm32- ... GS450H.cpp )

Line 580:
//mg2
htm_data[31]=(mg2_torque)&0xFF; //positive is forward
htm_data[32]=((mg2_torque)>>8);
htm_data[37]=htm_data[26];
htm_data[38]=htm_data[27];

The last two lines make htm_data[37-38] equal htm_data[26-27], which are always zero?!