Brakes and Pedals

When we were removing components from the car shortly after we got it, we took off the front and rear subframes and corresponding brake lines. Some of them got lost and we also cut a bunch when we were cutting the frame for the motor mounts. On top of that, the original brake rotors and pads were incredibly worn down and needed to be replaced. We just recently replaced pads and reran the brake lines and bled the brakes with new fluid. Now we can stop the car, which is always a good thing to be able to do.

On another note, we had to create our own pedal to integrate with the motor controller. We decided on a single degree of freedom design that allows the pedal to travel without hitting the brake all while properly engaging the throttle controller supplied with the motor.


The accelerator pedal is hinged at the bottom and moves a rod that is attached to the throttle controller on the left.


We also had to make it look interesting.

Generator

We just installed the generator this week. It is a standard generator that would be used on a job site by a contractor. It can produce 10kW continuously and is just perfect for our needs. When we were looking at generators every model we found above ~5kW seemed way too big for our space because the dimensions were always given with the frame included. To get an accurate measurement, we had to call the factory and have them measure the unit directly. Once we knew how big it was, we ordered it knowing we had about 2 inches of side to side play and we had to cut out the rear bumper area.


This shows the vertical and horizontal supports for the generator to sit on. We made the design modular to allow the generator to be removed without any specialized equipment.


Here it is! It fit almost too perfectly. If it was any bigger it would not fit.


We got it to fit without entering into the plastic bumper area.


One final view from above.