Fiberglass fitting of the Whale Tail

 After re-working the corners i was finally able to get a good fit. Next up Paint!

Temporary cooling system to keep the IGBT temps down

 Salvaging a few parts to complete the cooling loop. The Blue G49 screamed fish tank tubing. if it works, I'll replace the zip-ties with proper mounts.

repairing the headliner

da tunes

My dad convinced me to just drive it.

The motor is quiet, so I noticed the speakers were toast.

Practice fiberglass layups...

Trimmed

with tweeter

installed

looking stock.

rear suspension rebuild

After re-building the rear suspension to replace the bushing (a half dozen times or so) and setting the ride height for the difference in vehicle weight, I now know far more about torsion bar suspensions.

I decided to go with elephant racing poly bronze bushings in the rear swing arms and rebuild the rear brake calibers since one was sticking. We should be ready for the summer!

Preping a Tesla Model S small drive unit

Getting ready for an eventual drive unit swap. working on axles, but I got Damien Maguire's logic board installed and ready to spin.
https://www.evbmw.com/index.php/evbmw-webshop/tesla-built-and-tested-boards/tesla-small-drive-unit-logic-board-built-and-tested

The only real challenge was desoldering and re-soldering the current sensors without damaging them, but Damien has some great tutorials on his youtube channel.
https://twitter.com/EvBmw
plus the code is open source!!
https://github.com/damienmaguire

Catching up over the past year (Level 2 Charging and a 12V DC/DC converter installed)

 The rear "engine" compartment has gotten a bit more crowded over the past year, I finally got around to programming the MCU to control the Brusa over can bus and can successfully charge the pack, sequencing precharge contactors all from an ESP32 MCU (the code ceased to fit in the Arduino Uno that I started with). At some point, I'll probably move to an STM32F4 micro that supports auto-code generation for some more advanced State of Charge estimation algorithms.

I also learned what happens if you apply a reverse polarity to a Chevy volt DC/DC converter module. As you might suspect it lets the magic smoke out, it was actually quite spectacular and loud. So for the 2nd try, I opened up the unit and confirmed which was the proper positive terminal, along with adding additional lower current fuses in the HVDC wiring. Details on the converter can be found here
media3.ev-tv.me/VoltAPMUserGuide.pdf
fortunately many units are available on eBay.