[ausev] This weekend?

Thu Aug 3 20:26:51 GMT 2006

I'm reminded of how we pulled the engine out of the MR2.  We set the
engine down, and then used an engine hoist to lift the car.  We then slid
the engine out from under  (it was set down on cardboard to make this
easier).

How about something like this?  :

A) Start with the truck on the ground
B) Insert a palette jack from the side between the wheels, raising it to
support the pack
C) Place a set of supports (maybe just wooden blocks) under the pack so it
will be supported just above the lowest height of the palette jack
D) Unbolt the pack from the truck and lower it with the palette jack until
it's resting on the supports
E) Remove the palette jack
F) Roll the truck away to expose the pack, which is sitting on the ground.

  --chris

On Thu, August 3, 2006 2:12 pm, Derek Bridges said:
>     What we learned at the first attempt to change out the battery pack
> was the need to do our planning in some detail. We could take a shot at
> removing the pack on Saturday if Roy can make arrangements with his
> friend's shop before then but I would recommend that we meet on Sunday
> strictly to do some detailed measurements, research and planning. It
> would just suit my overly analytical, under achieving nature to wring
> out the thinking and the talking before starting the lifting.
>     The thing that bothers me most is the danger associated with lifting
> the truck several feet in the air then having people stoop under it to
> do strenuous work dismantling the battery pack.  Tall tripod jack stands
> are available which have a range of about 55" to 83". If the shop with
> the lift has these stands it would make things more nearly safe although
> I'm still not crazy about the idea. I would prefer to find a way of
> moving the still-loaded battery pack out from under the truck. The pack
> is longer than the fore-aft distance between the tires so it would have
> to come out from the front or rear. We could use the winch to pull it
> out if it were on some casters or if it were on wooden blocks on some
> kind of relatively low friction surface.  Nylon slider pads on sheet
> metal?  If we built a dolly with 2 each, 200 lb rated casters under each
> of the 6 battery pack hard points, we would basically be within the
> caster ratings, not withstanding the heavier loads at the ends where the
> batteries are stacked two high in the pack. If the dolly was on a flat
> concrete floor that was long enough, we could then pull it out pretty
> easily.  Getting the pack and the truck aligned for re-assembly is a
> whole nuther topic.
>     I also like the idea of raising the truck in Mark's garage where we
> can take all the time we need. We  could raise it incrementally and
> place the tires on big blocks made of railroad ties or landscaping
> timbers.  Complicated and time consuming and maybe not even safe but I
> find it appealing.
>
>     Which ever approach we use, we should take some measurements to
> answer the following questions before lifting any thing.
>     1. Exactly how high does the truck need to be raised in order for
> people to work under it?  How tall are the batteries, how heavy are they
> and how much vertical space is needed for disassembly?
>     2. Is there enough Horizontal room under the truck to place tall
> jack stands and still not interfere with the battery pack or with people
> working on it? Take into account the footprint of the jack stand and the
> limited number of hard points where it could attach to the chassis or
> axles.
>     3. How high does the truck need to be raised in order for the
> battery pack to be dragged out from under it going out the rear? Going
> out the front?
>       4. How much space is under the pack? Current thinking is to put
> blocks (or a dolly) under the pack and deflate the tires enough to rest
> the pack on the blocks.
>
>  From the budget-is-no-object department:
> Here is a picture of a portable lift that does exactly what we need.
> Wonder where we can rent one.
> http://www.bencostuff.com/images/lifts/alm/we18-2.jpg
>
> Here is a close up view.
> http://www.bencostuff.com/images/lifts/alm/we18-1.jpg
>
> Here is how we will end up doing the job.
> http://www.bencostuff.com/images/past%20installs/large/Not%20a%20good%20idea.jpg
> I have seen the same picture posted elsewhere with the caption "Why
> women live longer than men."
>
> Lots to think about. Any comments? Suggested meeting time?
>
> Derek Bridges
>
>
>
> mark witt wrote:
>> Hi  all....well the batteries and the NGS tester have arrived at my
>> house.
>> I'm still unwrapping them and charging them up. I am available both Sat.
>> and
>> Sunday. Maybe we could drop the pack on Sat. and transfer the truck and
>> old
>> batteries and case back to my house. On Sunday afternoon we could gather
>> in
>> my garage to check everything out and see what we would need in addition
>> to
>> what I have. I will post some info directly related to the "Ranger
>> Reformation" project so everyone can see the fun we shall be having.
>> (Chris
>> has seen it) I still have the truck loaded on the trailer from Sat.
>> night at
>> the movies.(WKTEC) I'm working on a garage closer to my SE Austin house
>> but
>> the NW Austin one that Roy lined up may be the one we use...Thoughts?
>>     I will be out of town from Aug. 11 maybe through Sat. the 19th..so
>> getting the truck going for the Ball prob. wont happen but it would be
>> great
>> to drive it around at the Roundup...Ranger Witt
>>
>>
>>
>>
>>> From: "Chris Robison" <eeyore at phototropia.org>
>>> Reply-To: eeyore at phototropia.org,        AustinEV announcements list
>>> <ausev at austinev.org>
>>> To: ausev at austinev.org
>>> Subject: [ausev] This weekend?
>>> Date: Wed, 2 Aug 2006 17:36:31 -0500 (CDT)
>>>
>>> It's looking like my garage is going to be closed this weekend, at
>>> least
>>> at the normal time on Saturday afternoon.  I'm wondering if there's
>>> some
>>> alternative venues that might be open instead.
>>>
>>> As far as I know, the two projects nearest to being on the road right
>>> now
>>> are Mark Witt's electric Ranger (needs new battery retrofit, Witt has
>>> the
>>> parts!) and Erik Bigelow's Cabriolet.
>>>
>>> Either or both of these would be fantastic to have available for show
>>> at
>>> the Sustainable Shopper's Ball, and/or the Roundup in Fredericksburg.
>>> Do
>>> we have a possibility for a work session on these, or any other
>>> vehicles
>>> this weekend?
>>>
>>> I'll probably have some time on Sunday to pitch in...
>>>
>>>   --chris
>>>
>>>
>>> _______________________________________________
>>> AusEV mailing list
>>> AusEV at austinev.org
>>> http://www.austinev.org/mailman/listinfo/ausev
>>>
>>
>>
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>>
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