samurai

Another quick update, this time about the new indicator stalk. The high beams were not working and after some wiring and fuse tracing I found out that the culprit was the indicator stalk. The first plan was to open and fix the original part but they are very expensive. Luckily, they are exactly the same as the ones in the Renault Express vans so I ordered a brand new for under 30€.

Just a quick update about two new sheet metal parts: a tray for the junction box and another one for the throttle pot, made from 2mm thick aluminium. It's a pretty simple design and the two parts are super lightweight. You can see that the junction box tray had to be bend a little but that's okay. The pot tray also needed an additional 1cm of length to add tension in the cable but that will be for a 2.0 version.

With most of the mechanical work done, I'm now moving on to the electrical side of things. I started by cleaning up old stuff, fixing the indicator stalk and designing some trays for the pot and the junction box.

Great milestone achieved! The hyper9 motor is installed and secured with the custom made mounts, after some struggling and sweating.

I was certain that today I would be able to install the hyper9 motor in the Samurai engine bay. However, there's always something that delays the project :) This time it was the clutch pressure plate bolts that are missing in combat, so I had to order new ones.

I've made some small but needed adjustments to the aluminium adapter plate. Since I didn't model the fasteners in FreeCAD, I missed some bolt heads that don't clear as they should. My solution was to replace those bolts with countersunk ones.

The adapter plate arrived and is already secured in the engine bay! Major dimensions are okay but a few adjustments are still needed.

The aluminium adapter plate is machined and ready to ship. It should arrive early next week and I can't wait to try it!

The several motor mount custom parts are built and assembled! The measures are almost there and it seems sturdy enough. Here's a quick look at the contraption that will secure the motor and the controller.

Welcome to engine mounting design 2.0. I started thinking that the previous design with a cradle wouldn't work well with the hyper9 motor. So, I decided to ditch this idea and design another solution using traditional rubber mounts.