Mate the transmission to the motor

We need to put these to pieces together.  Working from the inside outward.

Motor 24 tooth spline

Transmission 28 tooth spline

Spline coupler 24 teeth

Clutch disc plate 28 teeth

The plan is to cut out the center of the clutch plate and weld it to the spline coupler, Then cut the assembly to length.  BETTER SUGGESTIONS?

Then we need to create an adapter plate to connect the motor housing to the transmission housing.  At the same time we will drill and re-tap a stripped thread in the bottom of the transmission housing for the lower torsion mount to the frame connection.

The adapter plate needs to be of minimal thickness as the total assembly will just fit inside the engine bay.  The good part is the adapter plate that will go on the other end of the motor will be directly under the right engine mount making the connection very easy.

Both of these plates should have attachment points for the Azure controller to vibration mount to the motor/transmission assembly.

This phase of parts creation will be done in CAD.

The "For Sale' page, check back for updates.

To keep things together, we will update this page with all the For Sale items even as time passes.

For Sale:

Fuel tank.

Fuel tank , apparently installed at 9:17 am on May 5, 2003.  Fuel pump, filter, straps, evap. pump, and lines included, all items working before removal.

Engine.

Engine, Code:AVH 254105 Mfg. April 1, 2003 I think the serial number is (0 or 9)37129717C  All items working before removal. See 1st day of tear out for video of engine running, note that it is loud because the exhaust had a hole just past the down pipe.

Alternator.

Items working before removal. See 1st day of tear out for video of engine running.

Secondary air pump.

Items working before removal. See 1st day of tear out for video of engine running.

Starter motor.

Items working before removal. See 1st day of tear out for video of engine running.

Power steering pump.

Items working before removal. See 1st day of tear out for video of engine running.

Slave clutch cylinder.

Items working before removal. See 1st day of tear out for video of engine running.

3rd day of tear out.

Remember to open the fuel door, and roll up the windows before removing the power...

Today we removed the engine and several other components.  I am working on uploading a video of the engine removal, the phone was confused and the image is upside down...

The pile of parts grows, not the shifter lever

This picture is here as a tribute to a friend that had a '60's Mustang that I remember from childhood.  It was special because I could sit in the back seat and they would drive down the center of the road so I could see the center road striping through the shifter linkage.

A running 2003 VW Golf GL 2.0L engine for sale.  Thank you to Jim Sisco for the use of the hoist!

UPDATE:  The engine was taken to the local junk yard for sale.  Unfortunately the engine was dropped off at the yard hours before a fire went through the facility, no paperwork had been processed and the engine was lost including any funds toward it. :(

Plenty of space for a motor and batteries.

We won't have a shift lever in the car, but will be able to shift manually.

I hope to upload a video of the engine removal, but need to figure out how to flip it back upright first, the phone has it all upside down.

End of day three.

2nd day of tear out

Remove rear suspension to get fuel tank out.

It is good to have helpers that can hold up an axle.

Yup, if you remove the rear suspension the tank comes right down with it.

I am sure it saved VW a nickel to make one big tank, but we did not expect to remove the suspension to get it out.
We will do some rust removal and painting of the suspension before putting it back in.  We need new springs and shocks anyway so it was only two large bolts and disconnecting the brake line extra.

1st day of tear out

We recorded a proof of life video before taking the engine out.  We aim to sell the engine and as many other components as possible.  It is a bit loud as the down pipe flex coupling has a hole in it.

Going up

Disconnect battery

Remove hood starting with windshield wiper sprayers

Front exhaust pipe, you can see the frayed wire where the flex pipe has a hole.

This muffler is huge.

Battery and air cleaner box removed.

This is behind the right rear wheel well liner.  The right side is fuel tank, the center appears to be an overflow and fumes pump.

End of day 1, heat shields, exhaust system, some of the fuel lines, air box, battery box.

1st recycle yard visit

We combined a few trips together this weekend.  My wife needed to be in Columbus Ohio so I drove her to Columbus, then Friday morning stopped in at Wirthman Bros., Inc. auto recycle yard to get many small plastic pieces to replace the parts damaged by previous owners.  Then I drove to Michigan Friday afternoon to pick up the motor, DMOC and many other EV parts pictured on the "Bulk parts find..." page. A visit to a recycle yard Saturday yielded nothing, I had called them from my home in Illinois earlier in the week to see if they had any cars that matched mine and was told they had several.  Upon arrival they did not know the difference between a VW BUG and a VW GOLF.  All the parts they pulled for me were from a Bug, very disappointing.  The yard actually had one Golf that was stripped clean and ready for the crusher.

From the Wirthman yard I was able to retrieve:

A radio, the local VW dealer confirmed my receipt from the yard and gave me the code at no charge.



A handful of fuses and relays, this one is or the DRL's



Plastic clips, bumpers, and seals for the hood



I got several locks so we can take the wafers out of several to get the proper combination to match the current keys we have.



Four fender well liners


Several dashboard switches to give control options for the EV.  Note the heated seat roll switches, we do not have heated seats, but there are 6 positions on each switch.  What do we want to use them for? Options considered so far:
1.  Since there will be no clutch, we could have the motor match gear speed by selecting the gear we wanted.
2.  We could use it to change the computer output display in the dash, how many outputs do we need?  Using both of them we can get 36 outputs.
3.  We could set regen values 0-5
4.  We could set max torque values
5  ??? You tell me, what do we want to be able to do on the EV?
6.  It also occurred to us that we could use the center hazard button to engage the hazards at the same time as dropping the 12v to the inverter as the E-stop.  Good idea, bad idea?



The headlight switch including the foglight option




I stopped to see another friend along the trip and we spent some time in his garage.


There was another HUGE black car of this vintage but is was several feet longer and not convertible..

Sorry, there were another 4 that I spent too much time looking and forgot to get a picture.  One was HUGE and black from the early 50's is my guess.