It’s been a while, as I’ve been in Dallas both for work and family matters. I’ve also taken some time to help out with other goings on locally; Mark Witt is still working on his Ranger battery pack conversion which is facing some unfortunate setbacks, and Erik Bigelow recently led an “EV Intro” session which was well received by some new AustinEV members. Rob’s RAV4 conversion is proceeding rapidly as well, and next weekend if everything works out, I’ll be over there again helping with a welding intro for those who want to try it out.

On my own project, I have some good news. (Read on …)

This evening Phoenix Motorcars held their second of two public events unveiling what they’re calling simply the “Sport Utility Truck” or SUT. The first was in LA; this one was in Dallas where several AustinEV members travelled to catch the show. What we saw was indeed a pickup truck with seating for 5, and there is also an almost identical SUV version in the works. I was pretty impressed with the vehicle in general, but was disappointed by some of the things the presenters were saying about it.

(Read on …)

Well, tonight I’ve had one of those evenings when you discover that your fine, shiny 2-dimensional plans have been complicated by the subtleties of a 3-dimensional world. For reasons that may include the existing frame not being a perfectly square C-channel, despite my best efforts I have an error in my measurements and therefore in the shape of the new frame segment. A very slight error, but one I intend to correct before I go any further.

(Read on …)

A good bit of work, but not much to show for it. I’ve roughly cut out the first two pieces, and in doing so I can tell pretty clearly that I currently lack the skill to do an accurate cut with the plasma cutter. Even with wheel guides on the torch head, I can’t move my hand steadily enough to prevent skips (where the torch does not cut all the way through) or re-welds, and I doubt I’d be able to follow the line perfectly. This is a shame, as I’ve found the cutter produces a surprisingly even and precise edge with very little slag underneath, if it’s moved smoothly. This cutter can be upgraded internally for machine control (CNC); I’m really wishing I had space for an X-Y table.

Alternatively, what I could really use right now is a metal-cutting bandsaw. I have one that belongs to a friend, but it’s not made very well and despite attempts to adjust it, it’s developed a habit for throwing the blade — every few seconds. It’s probably not really up to the task, and I’m reluctant to drag it out of the attic just to realize that it’s worthless. I may end up using a jigsaw, but I really don’t like that idea either.

Anyway, here’s what I’ve got so far.

At this point, I now have the pattern for the new shape of the frame, ready to cut out of 1/8 inch steel plate. How I got here from where I was last time, involved some important decision-making.

(Read on …)