Quick-ish update
I am going to keep this on the short side today. I did some more work on the coupling and got rid of the “ears” that were hanging from it. I have some pictures but they’re on my phone and I don’t feel like transferring them over at the moment. There is still a lot of work to do on the coupling, though, and I really need to figure out how or whom to get it done.
I also did some work on the brake pedal. I was reading in the service manual and found out that the device I had marked as the Regen Pot is actually the Brake Pedal Position Sensor. It sounds like if that doesn’t move at the same rate the brake pedal does, the brakes won’t work right. So, I figured out how to mount the sensor on the side of the brake pedal assembly.
At the suggestion of a friend, I made silicone mold of the motor shaft and then cast it in plaster with an eye toward using it to get an accurate inside spline somehow cut in the coupler. I actually made two of them; the first covers just the splines and the second goes all the way to the face of the motor. The second one isn’t quite round, so I don’t think it will actually be useful. I don’t think I really need it to go that far since the coupling won’t sit that far up.
I found the pieces I cut out of the firewall and I’m going to weld them back into place so the brake booster is properly supported. Or, maybe I can talk a friend into doing it since my welding is so barbaric. We’ll see.
I don’t have the CRX fixed up yet, but that is rapidly climbing up my list of things to do. Fortunately, gas is still relatively cheap.
Well, that’s all I have for now. I’ll keep you posted as things progress.
B
You are serious about everything your do. Fabrication is the terrifying part of all this for me you handle it with ease.
Thanks. The part that concerns me is running the high voltage cabling. I’m going to have to spot cells around the car to get them all in and they will all have to be connected somehow.