Judebert's EV Conversion Diary: Brushwhacked, part 7

During the week, I'd ground out a small aluminum block to use as a secondary bracket. It's just supposed to attach to the second motor mount hole and help keep the big bracket well-anchored vertically. With counter-sunk Allen bolts, it would look pretty sly.

Apparently, I can't hold a grinder straight. My block has tilted edges.

I did manage to get the 1/2" hold on top drilled. It took a trip to the hardware store to buy a tool sharpener, though.

Nathan came over and tapped the 1/2" hole, installed the chunk (so it would be in the installed position), and drilled the holes for the 3/8" Allen bolts. Then he took it off and drilled the countersink holes.

Yes, the bottom of the hole was a funnel, and yes, the Allen bolts have flat heads. It's not like this is all THAT important. It'd still work.

But the Allen bolts have 9/16" heads, and the biggest bit that will fit in my 3/8" drill is a 1/2" bit.

I found an extra broken bit when I came back. And the drill was stuck so the bit in it wouldn't come out. Apparently Nathan had some tool trouble, too.

Not daunted, he decided to re-insert the passenger axle. But he couldn't get it back together. Since the axle-nut is semi-permanently affixed, he just removed the whole steering knuckle and pulled it out. One of the u-joints on the end had come apart, and he couldn't get it back together.

End of day.

That left me with four things to do:

1. get a 5/8" drill bit with a 3/8" shank,
2. get the old bit out of the drill,
3. get a mechanic to remove the axle from the steering knuckle, and
4. get a new axle

Nobody anywhere has a 5/8" drill bit with a 3/8" shank suitable for drilling aluminum, and there's not a machine shop anywhere nearby that can do the job; I'll have to get a 1/2" drill (won't Eri be pleased? ) Lowe's couldn't get the bit out either; I had to leave the drill with them. They eventually got it out; I retrieved it yesterday. The easiest part of the whole thing has been new axle: the AutoZone down the street had one in stock for $60 + $20 core.

The mechanic wasn't open by the time I got to him yesterday; this morning he attacked the axle nut with a pneumatic drill he called "Big Bertha" ("450ft-pounds of torque!") and it came right off. $20. Unfortunately, I got grease all over my nice polo shirt. I didn't have anything to change into, so I went to work greasy. Ick.

BUT I've got almost everything we'll need to attack the problem on Saturday.

We'll have this thing running yet!