This blog documents the restoration, and conversion, of a 1965 Humber (Singer) Vogue to a fully electric vehicle. The Vogue will be powered by an 11kW(modified), 3 phase industrial AC motor, controlled by an industry standard Variable Speed Drive (VSD) or Inverter. To be able to produce the 400 volts phase to phase the VSD will need about 600 VDC of batteries. A big thanks to the contributors on the AEVA forum:

Thursday, February 7, 2013

Issues to Resolve - not quite finished

A number of people have congratulated me on finished the Vogue. Getting Vic Roads approval was a goal but unfortunately isn't the end of the project.
Back at the end of 2012 this ended one of my posts:
"My target for the moment is VicRoads approval so everything else can wait. I pick up the polycarbonate partition for the boot tomorrow and I'll be preparing the car for inspection over the Christmas to new Year break."

So now it's approved but not quite finished.
Known issues:
  1. Tailshaft speed vibration - I suspect differential pinion angle. This is the big one and stops me driving it too much until it's sorted.
  2. Brake master cylinder. Pedal is not returning fully. Not a big issue but indicative of a problem. I have a spare (I think) so I'll restore that and do a changeover. We caused this when we flushed through new brake fluid - a common problem in cars that haven't been driven in a while.
  3. Winding window outside weatherstrips. I need to dis-assemble all doors and replace the clips - they're falling off inside the doors. Getting the correct clips is a pain as the originals don't fit due to a difference in the weatherstrip. (I kind of knew I had a problem when I fitted them then warned the family not to wind the windows all the way down.)
  4. Slight "thump" when starting from stationary. This is a controller programming issue. It's fine going on and off regen when actually moving - it's just when starting. Annoying.
  5. Front end work. Knox Tyrepower noted that while most of the front end was fine, there are a couple of bushes that need replacing. While at it, I'd like to get prices on lowering the front about 20 to 25mm.
  6. Remove and modify all 12 chargers. I am not at all happy with how they balance the packs at the end of charge. I have modified one of my spares and it worked well so I now need to remove, modify and replace all chargers. The rear ones are easy - the front not so. While I am at it I am going to replace all M4 nuts and bolts on the front controller tray with rivnuts so I can get individual items off the tray without having to remove the tray as I have to now.
  7. Front parcel shelf (below the dash). Laurel wants it back in. It doesn't really exist anymore as it was a total wreck. I kept the metal front though.
  8. Car Radio and speakers. Also mounting for the little Lenze (motor controller) keypad and display.
  9. The "other" controller - the 75kW version. I have all the parts for the upgrade but it's pretty low down on the priority list. Unfortunate, as more power would be nice.
There is other stuff but they are the main issues.
We are renovating my daughter's bedroom while she is away for the next two weeks so the Vogue fixups will wait until that's done.

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