DIY Paint Experiment Conclusion

Here is a closeup shot of one section of the hood.  You can see the reflection of my hand (thats a reflection and not a hand print)  which will give you some idea of the quality.  No brush marks, even tinting, very high gloss after some elbow grease and polishing compound (not buffing compound). I'd call this experiment a success.   I'll let you know in a year or so about durability, but so far everything that's been claimed about this technique has been spot on true, so I have no doubts that this will also be durable.  

Out in the sun 

Paint Job on a Budget

As you know by now, this is a budget build of an electric car. The challenge is to find the parts used or to rebuild what I can find cheap. I hope to find a used forklift motor, build an Open Revolt controller and power this with either used and refurbished batteries or off the shelf deep cycle batteries from Walmart.  And, although this is a budget build, I don't want it to look like an amateurish effort. One of the things I've wanted to try for awhile is to paint a car using a technique first described on the Mopart forum board. You can find that string here. 

Since this first appeared on the Internet, a number of folks have put this technique to the test including the folks over at Hot Rod.  So, since it looks like my hunt for bargain parts is going to take me awhile, Abigail and I decided to start our own paint experiment on the hood of the Volts-Wagen. 

In case you didn't want to hit the links I included, the way you do this budget paint job is to use Rustoleum thinned to an almost watery consistency with mineral spirits.  You apply the paint with a high density foam roller, and foam brush,  wet sand and repeat about six times.  Finally you finish the job with some quality time with polishing compound and a buffer.  Lots of money for a professional paint job is replaced with lots of labor in your own garage. 

Today we applied the first coat after a good wet sanding with 1000 grit sandpaper.   The first coat turned out even better than we expected.   If this turns out like we would like, this is going to be one good looking EV.  

The pictures don't show up with the actual color.  We'll try to get pictures outside in a few days as we update our progress.   

This is the first coat, and although the picture doesn't show it very well you can see a little of the original gray color through the sail blue paint.  Already though, you can see the gloss and this is at a tacky stage.  

 

Here is a better view of the first coat.  All the people who have done this say the first coat always looks bad.  So, it looks like we are doing it right,  

Transmission Time

It's been a crazy week at work and I haven't had the energy to do too much on the car this week, but James and I did manage a few hours removing the transmission and measuring clearances. I also got a DVD that I ordered last week on how to build an electric car (see below). It's a great resource with some very clear explanations. It's not a technical manual. I already have two of them, but it sure does help to see pictures and reinforce some of the concepts of how all the pieces go together. If you are going to take on a project like this, I highly recommend this DVD.  

One of the challenges is how to attach the motor to the transmission. The first thing you need to do is to make a template of the bell housing of the transmission. VW made this easy for me with a pre-made one that served as a sheet metal dust shield between the engine and transmission. I'm wondering if I can just beef this up a bit by welding some steel reinforcement right on the sheet metal cover and then just attach the new electric motor to this reinforced dust cover. You can see in the pictures below what I am talking about. I've got a little time to ponder this while I continue to take off unnecessary parts and continue to look for an affordable motor.

So, if you know where I can get a used forklift motor no more than 18 inches long close to Butte Montana, please let me know,

The dust cover and the clutch plate,  I'll punch the splined female center out of the clutch plate and use it to build an adapter to connect the motor and transmission.  Electric cars don't need clutches, so for simplicity's sake I'll most likely not use the clutch plate or the flywheel,  

Here is how it fits on the face of the transmission.   It's already centered for a motor to attach,

I highly recommend this DVD you can get it over here

The Dirty Deed is Done

It took a little coaxing but that internal combustion engine is out of the Volts-Wagon. Boy did I feel dirty afterward. I must have spent an hour in the shower last night trying to get clean. I don't think my hands will ever be free of the carbon encrusted grease that seems tattooed under the skin covering my knuckles.

The engine and various other part are now listed for sale on Craigslist. So if you need a decent VW engine, come and get it.

Deconstruction Begins

Step 3: Start taking things apart

Today James and I got our hands dirty and started tearing the guts out of our Volkswagen a.k.a. Volts-Wagon. Already this is turning into a great project with James becoming a cracker jack wrench turner. Today he learned the difference between standard and metric wrenches, and righty tighty, lefty loosey. Deconstruction seems to be the perfect job for an 8 year old.

Attacking all that unnecessary stuff

Maybe he'll try a different angle

 "Lets call it a night, I'm getting tired"

The engine is still in, but it is already for sale.  At this rate it will be out this weekend. And I accomplished something I never thought would happen, I wore the boy out.  

The Volts Find A Volts-Wagon

Step 2:  Get your spouse to let you spend a little cash on a donor car. 

Thanks to Craigslist, we found a 1991 VW Golf about a mile from our house for 150 bucks.  (picture below)  The VW on the front now stands for Volts-Wagon.

Listen in as Kathy and I discuss the latest EV developments and contemplate our next move. 

Carl and Kathy Discuss Building an Electric Car

Step 1:  Convince your spouse that this is a good idea