So I worked this weekend on running the existing throttle cable to the throttle box for the electric motor. It has to make a turn from horizontal down the length of the car to vertical where the throttle box is mounted in the picture I have in the single-page “Build your electric car” manual.
So I figured the best way to do this is to put in a piece of sweep-90 pipe (90 degree turn in a quarter-circle) that would steer the cable up to the right place.
Then I looped off the cable using a wire clamp, and hooked it to a tiny turnbuckle so I could adjust it’s tension to the throttle box.
So here’s the problem. I test fitted the throttle box, and what I found was that when I push the accellorator down, it pulls the throttle box lever down. Yay!
However, when I take my foot off the gas pedal though… the spring loaded lever is not strong enough to pull the cable back up through all that friction in the sweep-90.
In practice, this is bad because the car never stops accelerating and the car drives into things younger and stronger than a 1968 Beetle, hurting the driver severely and requiring expensive replacement parts.
So… I gotta figure out a new way to do this.
To be honest, I’d really like the next step of this project to be the really obvious easy step.
Steps to complete:
- Fix throttle problem
- Mount other new electric parts
- Get normal electrical system working
- Upgrade suspension
- Install batteries and wire up the stuff.
- Drive to work, solve world energy problems, spit on Dick Cheney, make love to a rainbow