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  1. L

    FOSSHW Category L7e Hybrid EV (full build: not a conversion)

    i completed the first wrap of the rear section, sufficient for it to be stable. it's now outside, and the front has been brought in. nose-down in the picture below, rather than tail-down. the roof (right, near door) fits nicely, i will show that another time. currently i am in "repair" mode...
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    FOSSHW Category L7e Hybrid EV (full build: not a conversion)

    here you can finally make out the outline of part of what is "a car" because in 2D image form there is a panel attached to the space-frame. no mid-point brackets are attached to bamboo pipes, yet, i forgot about them, they can be added easily (before foam that is!). the underside dacron has...
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    FOSSHW Category L7e Hybrid EV (full build: not a conversion)

    the first panel has been created, it goes at the rear midde top, at the bumper, where a boot lid would normally be. you can see the metal brackets currently hot-glued in place, and the side-on picture shows that this is a compound curved shape. most slats are doubled-up, with bridges 9mm in...
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    FOSSHW Category L7e Hybrid EV (full build: not a conversion)

    bolts are attached to the roof! they go on and off cleanly, there was some resin dripped across the Nodes and the bolt threads (eep) which fortunately separated. the M10x75mm bolts cast shadows at the bottom of the picture. remaining Node sites i will use back-to-back L-Brackets with M5 bolts...
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    FOSSHW Category L7e Hybrid EV (full build: not a conversion)

    okaay this is the roof-line / top-doorframe point just behind the right passenger head. an M10 bolt head is encased in MBFG Kevlar-epoxy resin, and it comes down through two 30mm long 12mm OD 10mm ID Stainless steel 316 tubes (cut from a 3m section), finally an M10 nut with a Nylon lock insert...
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    FOSSHW Category L7e Hybrid EV (full build: not a conversion)

    two assemblies (rear, floor) currently resting under gravity, a bit of a pain to slot together. bolts need to be affixed now. and this is one that i have messed up. see how it is at a slight angle? if there were two tubes and the bolt slid into them it would not be a problem, but in my...
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    FOSSHW Category L7e Hybrid EV (full build: not a conversion)

    been busy laminating. this is 1 layer kevlar underneath 2 layers industrial hemp with 5in x 50 mm MBFG Kevlar tape at each end and double helix garden twine to finsh it off. Wow the hemp hessian drinks resin: that was 75 ml gone in a flash. put the frame level on the floor as i have to...
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    FOSSHW Category L7e Hybrid EV (full build: not a conversion)

    wha-howw the epoxy-kevlar phase is taking time. at the rate i am going it will be 2 MONTHS full-time to complete. i have to find ways to speed up. will experiment with different layering strategies and report back what worked well. MBFG recommended using foam pads (non-styrene ones when using...
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    FOSSHW Category L7e Hybrid EV (full build: not a conversion)

    i'm packing out the... concave(?) parts in the 3D printed PLA Nodes with crumpled paper and masking tape. this leaves no areas where when the Kevlar is stretched across it could leave a large air pocket or just as worse require significant amounts of kevlar and epoxy to fill up the holes. given...
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    FOSSHW Category L7e Hybrid EV (full build: not a conversion)

    ok so this is the very first wrap session, a few layers on each node, you get the general idea of how this is going to go: QTY 135 Nodes, each one probably 3 metres of 50mm wide Kevlar "belt", it's a hell of a lot of kevlar and resin, and that's just the Nodes: the pipes need a minimum 3 layer...
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    FOSSHW Category L7e Hybrid EV (full build: not a conversion)

    done, the last third, bumper is in (top of picture) on both sides. i'm just going round reconnecting rods that have pulled off under tension, using twine to put them under compression. some areas are not going to connect (roof line) no matter what. there is a regular 6mm gap that will not...
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    FOSSHW Category L7e Hybrid EV (full build: not a conversion)

    i had to scoot to FOSDEM2023 so didn't get a chance to complete the rear section, but managed about 30% remarkably quickly, by switching to hotglue. i was somewhat reticent to use it because it is so much stronger and could soften the PLA but it works well including the usual dismantling after a...
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    FOSSHW Category L7e Hybrid EV (full build: not a conversion)

    hargh, wha-howw that was risky and awkward: with 15 sticks of hotglue i got the roof, floor+doorsills and driversupport+backbox separated. the roof came off easily because it was resting under gravity with very little tape: the backbox was properly glued on and a couple of pipes had vertical...
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    FOSSHW Category L7e Hybrid EV (full build: not a conversion)

    top windscreen line is in. separate bracing from the dashboard gives a triangular window port left and right of the windscreen, in front of each door. the "wedge" above the driver, onto the top windscreen line, really is very thin. this is basically phase 2 completed, phase 3 involves...
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    FOSSHW Category L7e Hybrid EV (full build: not a conversion)

    like this. the first picture shows the front wedge which has at its front the top centre of the windscreen. the picture on the left is the isometric screenshot from OpenSCAD, marked up as a build diagram. this one was a total pain in the ass to assemble as two roofline parts needed hotgluing...
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    FOSSHW Category L7e Hybrid EV (full build: not a conversion)

    okaay so a decision on the roof construction is quite easy once the decision was made to go 1930s "sports convertible" high door sills with gull-wings: from the driver position a central front-running "bridge arch" goes over their head, across to a toblerone (wedge) shape that has the windscreen...
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    FOSSHW Category L7e Hybrid EV (full build: not a conversion)

    after seeing that mercedes pedal car i realised that one of the key advantages of gull-wing doors is that there is a central roof portion that provides significant structural strength: the parts that come down from the roof down to the door-frame are much stronger. this gave me an idea to...
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    FOSSHW Category L7e Hybrid EV (full build: not a conversion)

    creating three sections, this was the original plan for the mid-section: however the complications involved in the sheer overwhelming number of epoxy-bamboo-bridges and the lack of stability led me instead to cut the front off at the floor-line. after staring at the back part for over a day...
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    FOSSHW Category L7e Hybrid EV (full build: not a conversion)

    i'm using loctite extreme glue here at this early phase, *not* the loctite extreme epoxy: the rubbery clear stuff, and tons of it (about a 2 to 3mm puddle surrounding each bamboo pole, i've got through 7 tubes already and i am only about 1/2 way done). then using painter's masking tape which is...
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    FOSSHW Category L7e Hybrid EV (full build: not a conversion)

    ahh got it. proper bolts. aluminium plates. okaay. quite straightforward as well. thank you. yes those cells you found are the exact ones i got. 19 of them were GBP 1300 including shipping and customs duty so yes, ways to look after them much appreciated.
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    FOSSHW Category L7e Hybrid EV (full build: not a conversion)

    ooo, ouch. yes ironically if you built this exact same vehicle in e.g. Belgium the only way i heard that it could be declared road-legal is to submit QTY 4of production units for testing, one of which will be independently crash-tested, one disassembled... yes *production* units. my friend is...
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    FOSSHW Category L7e Hybrid EV (full build: not a conversion)

    home-made jig raising the floor off the floor. from doing the CAD i know that the sides of the floor are 60 mm higher than the middle. have to think how to get this rigid so it doesn't break if moved. it's not in the least geodesic. the roof is, the floor is not.
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    FOSSHW Category L7e Hybrid EV (full build: not a conversion)

    first thing i did, over 15 years ago :) SVA is too stringent, MSVA as a "Heavy Quadricyle" is much less strict, because it is assumed that the occupants are going to treat the vehicle as what it is: a motorcyle. "cars" in this category include Ligier and Aixam Microcars, and more recently the...
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    FOSSHW Category L7e Hybrid EV (full build: not a conversion)

    kevin from divergent3d is the first to do this construction style "properly", with CAD software that checks structural load on the gedesic shape. i am to some extent winging it, and am prepared to overengineer and adapt (like you) :) one not obvious thing, down the length just like the Citroen...
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    FOSSHW Category L7e Hybrid EV (full build: not a conversion)

    appreciated: these 2.5kg aerospace cells come in a sturdy case already (as in: the packaging is reasonably beefy). these are not like the "pouches" which if you press them you leave an indentation. this would make sense given that in an aircraft or helicopter you would not want engineers or...
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