Elio Type Vehicle Resurection --- AKA the BEX

[JEBar]

Per Mark BEX ....

All the engine related wiring is done and fuse box mounted (red arrow), with a battery it would likely turn over with the key.
Battery is the next headache, trying to figure where to mount it, and it's not as easy as you might think, but I got to work it out.
The front is looking quite complete, mechanically that is, with most things in their place. Getting there bit at a time, after the battery will be fuel tank and fuel lines, it might even start up then.

[markiver54]

Seems like a good place for the battery might be somewhere in the back to add a little weight. Just a thought, if it could be done.

[JEBar]

Per Mark Bex ....

The battery has ended up behind the firewall, left of, and next to your clutch foot. The box the new battery came in was handy to figure the location

I always wanted it there, albeit a little lower, but was concerned the wiring loom junction box would have no room, and it's position is reasonably fixed because of the wiring loom, as is the fuse box.

So I whipped up a little battery cradle, drilled few holes, and Bob's your uncle.

For stability, being where it is very close to the front axle line, is close to ideal.

[JEBar]

Per Mark BEX .....

response to a question as to the size of the battery he has chosen : "No idea, it's 200 x 140 x 200mm (8 x 5.6 x 8") It was the smallest I could get length and width, but still with decent cranking capacity, because it's tall, and tall wasn't important."


comment related to reinstalling the computer/motor/dash wiring harness : "Had some electrical issues, a pet hate of mine, but found the problem myself. A small earth strap from the OBD2 port not ground, and the lambda sensor not connected, needed earthing through the exhaust header pipe."

the result .. can be seen in the video below

https://www.youtube.com/watch?v=4oZSqmCHg6k

[JEBar]

Per Mark BEX....

Not many steps left, put the fuel tank in position today also.

[JEBar]

Per Mark BEX ....

it's a 3 cylinder ..

I put some petrol down the throttle body, but not a pop. Strange, and is why I checked for spark.

Not that concerned, I'll get the fuel system hooked up then worry if it doesn't fire.

[JEBar]

Per Mark BEX ....

I went in blind as regards to the gearchange cables, had no idea what I was going to do with them when I got to that stage. It turns out I got quite lucky!

The side walls of the brake booster firewall are just in the right spot and size for 2 holes for the 2 cables,

I went in blind as regards to the gearchange cables, had no idea what I was going to do with them when I got to that stage. It turns out I got quite lucky!


The side walls of the brake booster firewall are just in the right spot and size for 2 holes for the 2 cables, (picture 1)


... maintaining a straight line from the gearbox gear change linkages (red arrows, bit hard to see).(picture 2)


The black bracket that holds the gearchange cables, also supports the clutch cable, I fitted it, was an easy routing, and now I have working clutch


The donor went on it's side to get some bits I need.(picture 3)

[JEBar]

Per Mark BEX ....

There is 8 earth leads in the wiring loom, I had 6 earthed out, the issue was a small earth lead from the OCD2 check port that I didn't even see, and the lambda O2 sensor (oxygen sensor) in the exhaust has an earth but the header pipe wasn't earthed out to the engine.

Not mine, but here is a random header pipe with O2 sensor, I had it plugged in, but the pipe wasn't connected to the engine, i.e. not earthed out.

All good now

[JEBar]

Per Mark BEX ....

It will be a slow week sorry.
Today: I had to leave the factory because the new factory being built next door was using a crane truck inside, and filling my factory with diesel exhaust. I damn near conked out, so went outside and sat in my car for 10 minutes with the A/C on my face, and only when I walked back in did I realise it was full of exhaust fumes.
Tomorrow; I have to clear out some stuff from my factory such as my donor car bodyshells and other accumulated large junk.
Wednesday; I have a chance to meet a battery guy who's traveling through the next city over (that's Chengdu, famous for Pandas and chilly food) for a sit down for discussions surrounding future BEX electric versions.

[JEBar]

Per Mark BEX ....

I didn't go to Chengdu today as planned, so got some work done on the car, sort of ...
First issue: It is illegal to sell gasoline at a station to fill a drum/jerry can. Utterly ridiculous when you see how many motorcycles and 3 wheelers' steel tanks they fill each day. As I drive electric cars, I can't go and fill my car up, take it to the factory and drain it, and I've long since drained the donor car tanks in the shop.
So I dropped in to a friend's mechanical workshop last night, asked, and good news, he knew a guy selling 'black market' gasoline, and knock me over, it was 1 mile from my own factory!
So I rolled up to his little hideaway old factory in a back lane, and here was a 3 ton van truck with a large square tank inside, and a fully working mini pump with money and gallons display! ... and a line up of people! Was just a few cents extra for the service, and was quite amusing.
So I filled up the tank on BEX, popped the fuel line into a large plastic container, wound the motor over and .... NOTHING!!!
I spent all morning carefully going through the wiring loom, trying to figure what was missing or not plugged in, searching the internet for wiring diagrams and going through them, NOTHING, AGHH!
All darn morning. Then I saw it ... remember I cut 2 holes for the gearchange cables a few days ago, well the wiring loom for the engine computer was in the way of the drill, so I had unplugged it, picture below, and forgotten to plug it back in ... Some days you should just stay in bed ...
Afternoon was concentrating on clearing out the factory for the incoming goods tomorrow afternoon (some of my old projects in another factory I mentioned). Was overdue for a clean anyway. Must admit to some mild excitement seeing some of the old toys coming.