Build Session 23 (240 mins): Shaping the Adapter Plate

I decided to hold off on the dual motor setup for now in hopes of getting this truck up and running this year.

This weekend Jared, Chad, and I marked and cut the 1/2 inch adapter plate that connects the transmission bell housing to the motor adapter.

We used the Rigid band saw with a 3/4 inch Lenox Bi-Metal blade and a LOT of aluminum cutting oil. The cutting was slow going but the end result was worth it. After cutting we cleaned up the edges with the grinder, wire wheel, and a little filing. During the next build session we will drill the holes and bolt the bell housing to the adapter plate.

The adapter plate before we cut...

Clamping the plate down and then tracing the bell housing...

 

 The cutting is slow...Chad keeps the blade plenty lubed with aluminum cutting oil which definitely saved the blade.

  

 We used to brush to keep the oil where we wanted it...

  

 Still cutting hours later...

  

   

Pretty good for a 3/4 inch band saw blade...

  

I'm grinding down the rough cuts... 

  

  

Chad decided to hand file a bit.

  

  

Perfect fit...I like it. Its ready for drilling during the next build session.

 

Build Session 22 (60 mins): Another Coat of POR-15

Jared and I added a coat of POR-15 Chassis Coat black on top of the epoxy paint. The Chassis Coat provides UV protection (fade resistance) on top of the rust preventing epoxy coat.

Build Session 21 (180 mins): Epoxy Painted Battery Racks and Frame

This weekend Jared, Chad, and I had a productive painting session. In a couple of hours we managed to finish the welding on the rear battery racks. Then we painted the rear battery racks, rear differential, and frame with POR-15 Epoxy paint which should keep them from rusting.

Jared and my welding helmets.

Jared and Chad painting. Chad is a good friend of ours. He just graduated from High School, is an invaluable robotics club member on the team that we mentored and is a skilled machinist. Not bad for a teenager!

Starting from the inside and working our way out...

Remember how many months ago we spent a whole day prepping the frame with scrub brushes and the pressure washer...I think it was about a year ago. Wow, time fly's.

I even painted the frame underneath after laying out plastic on the driveway an taping plastic around the cab.

The epoxy paint goes a long ways and looks great.

Nice...

It looks amazing!

Chad got some POR-15 epoxy on himself...It should wear off in a few weeks. Sorry Chad. :)

Zilla Z2K Controller Finally Arrived!

Yes, it has been over six months since I have posted! I have been extremely busy with work and mentoring a high school robotics team. School is out and robotics is over for now. Work is still extremely busy but several EV discussions with my good friend Jared has helped motivate me to spend a little bit of time each week on the project...regardless of work deadlines. I hope to continue making progress and posting the results on a more regular basis.

But that's not the purpose of this post. If you haven't already guess from the title of this post...drum roll please...yes, after almost eight months of waiting THE ZILLA HAS ARRIVED!!! It makes me happy. :)