https://bmwcse.com/buildblog daily 0.75 2021-04-12 https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1564335853848-YBO3SBMR22XQJLQWXPYC/CSE-Banner-3.jpg The Build Blog https://bmwcse.com/buildblog/cruisin monthly 0.5 2021-04-06 https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1617635378389-JQ3N8UCTSDSWW3AIEUZM/Button-on-board.jpeg The Build Blog - Cruisin' It all started with a little PC board and a micro-switch. The same type of buttons found in a lot of your small devices. The round things are T-Nuts which will mount the board to the steering wheel. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1617635232072-LOIJSRMDOXXT48ZG4KLN/Board-on-wheel.jpeg The Build Blog - Cruisin' I tested the fit behind the wheel. This was with a taller button to check how things would work. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1617635489930-ZBCXPRC6P9O3X4O8X9MK/Board-in-place.jpeg The Build Blog - Cruisin' I then put epoxy to the face of the T-Nuts and positioned the board one last time. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1617635512657-73Z1ZH6PNNHRAJUU5L7W/Nuts-Epoxy.jpeg The Build Blog - Cruisin' Once the epoxy dried I could unscrew the board from them. I had to shave the edges of the left and right one to make room for our housing. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1617635593783-5Q8XWHXC2QNG51HRQFAU/Board-Assemblies.jpg The Build Blog - Cruisin' Then I wired up both of the boards with wire leads that will pass through the steering hub then into the console. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1617658153355-RULJE5I44DYFTHKXONRZ/Board-Box.jpeg The Build Blog - Cruisin' I 3D printed a couple of small housings so that things will look clean behind the steering wheel. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1617635645491-V2J1SYZXMT7N6FYREVAJ/Button-Attached.jpeg The Build Blog - Cruisin' I used small black button caps which I shaved with a Dremel so that they fit nicely in the space. They are flush with the surface of the steering wheel, and your thumb can comfortably press them while driving. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1617635682210-44XO0GA5OKOK3M4D4H4U/Wheel-Ready.jpeg The Build Blog - Cruisin' The leads enter into the hub, and I used a multi-connector for the two cruise wires as well as the horn wire. The connector simply plugs into the modern BMW hub shown below. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1617635698705-2SLIFRTMSOZVKV4ANKSR/Steering-Column.jpeg The Build Blog - Cruisin' Because I am using a modern BMW steering column, there are plenty of extra pins passing through the rotating hub. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1617635764555-2EB1CYQDTVUQESWHRPPJ/Cruise-Complete.jpeg The Build Blog - Cruisin' https://bmwcse.com/buildblog/battery-management monthly 0.5 2021-03-30 https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1617051905305-XQ10NR8CO5QYSVINEE4L/Box+Coming+Out.jpeg The Build Blog - Battery Management https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1617054831730-ZGMNQBSLPFSJQ20CLQ3M/Orion.jpeg The Build Blog - Battery Management The Orion BMS is a fantastic unit which comes in various sizes to handle large and small battery configurations. This is as close as I’ve ever been to wanting to endorse anything. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1617054957299-WFPRZF6DZEIL015LAH3Y/Batteries.jpeg The Build Blog - Battery Management Inside our main box are twelve Tesla Model S modules (there is one hidden on the very top). There are two more modules in the trunk for a total of fourteen. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1617055139272-FUCW6ZL408WBTXGHJYX3/Taps+on+Batteries.jpeg The Build Blog - Battery Management The box is so tight with so little room, it was tough to make this wiring very pretty. But it is all secure and does the job well. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1617055061204-K930AMR89HZINPYJB7S5/Batteries+with+whips.jpeg The Build Blog - Battery Management After all the wiring was done we reinstall the box. Notice the whips exiting the box, which plug into the BMS in the footwell of the cabin. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1617054930523-32PYFJB67ERO4ZATNSE9/Brett+Enjoying+work.jpeg The Build Blog - Battery Management Brett has always gotten into his work. We needed to create new paths for our sensor wiring. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1617055427972-012GIXCR4BMK0KIG8VOA/Orion+Data.jpeg The Build Blog - Battery Management Once everything was put back together I could finally read the granular details of the battery cells. All those little 3.9 volts add up to the 333.5 volts you see above. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1617055768062-Q31UG1WSGXBYMT06X4JF/Shark-Porsche.jpeg The Build Blog - Battery Management https://bmwcse.com/buildblog/takin-it-to-the-steets monthly 0.5 2021-03-29 https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1603169414002-201G9Y9QGX4J61W91Q69/BMW-CSE-Side.jpg The Build Blog - Takin' It To The Streets https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1603199256730-09WTDG66H6J462HK2PAP/image-asset.gif The Build Blog - Takin' It To The Streets https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1603413444094-NS7T9E9WIUU9LOPSTLZR/Charging+Port+1.JPG The Build Blog - Takin' It To The Streets I’ve been charging the car with a temporary cord into the trunk. It was time to install the proper charging port. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1603413344371-4280YCO9ZLYGZQEHCVDG/Charging+Port+2.JPG The Build Blog - Takin' It To The Streets Now I can plug her in to charge the way one would expect. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1603459394157-JXBG5GV798SWD6LYRQMF/Alignment.JPG The Build Blog - Takin' It To The Streets Our wheels were aligned by eye during assembly, so it’s time to get a proper alignment to make sure everything is pointing in the same direction. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1603460601611-0L1USL6WRQK0ARNFBQB5/image-asset.jpeg The Build Blog - Takin' It To The Streets https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1603460626982-XWS0ENJOHUHCMQMGBXPP/image-asset.jpeg The Build Blog - Takin' It To The Streets https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1603460723900-SC7ZO9PU1TEUIQIJILGZ/image-asset.jpeg The Build Blog - Takin' It To The Streets https://bmwcse.com/buildblog/inner-space monthly 0.5 2020-10-20 https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1603144069846-UBRPTZHRF8ZCMPNJCFPY/image-asset.jpeg The Build Blog - Inner Space https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1602943553757-UW8BXR5YEKQLU9AMHYT1/Old+Dash.jpg The Build Blog - Inner Space The original vinyl dashboard had more cracks than a dried lakebed. And the foam inside had swollen and split in areas. Our neighbor by the shop does fantastic work so I walked it over. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1602943611438-4RISI4T5PYQM66IW0DDC/Finished+Dash.jpg The Build Blog - Inner Space After removing the vinyl and repairing the foam, I had them wrap the dash in new stitched leather. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1602944130974-7NZIT68Q2WRSI5MVARC6/Front+Dynamat.JPG The Build Blog - Inner Space https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1602944060891-T3J3KAF287EJLYQMTWD3/Door+Dynamat.jpg The Build Blog - Inner Space https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1602943899848-4XYDX4QOXZUAUWRYAVRY/Rear+Dynamat.JPG The Build Blog - Inner Space https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1603130055409-OUUJ3NIYZXO7WL53ZMR4/Padding+In-2.jpg The Build Blog - Inner Space Padding is glued down to the entire area. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1603130001574-TQ47M6GGWJPH0PAHL52F/Carpet+Going+in-2.jpg The Build Blog - Inner Space Then the carpet makes its first appearance. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1602944703536-EFPY7M03EUYZGNO8WMHO/Carpet+Done.JPG The Build Blog - Inner Space Cozy. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1603211005313-G80U0M5A7EXTJNFSVNGI/Dash+Complete.JPG The Build Blog - Inner Space Putting the console in brought together the dash to the shifter, which from this angle makes the car look totally complete! https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1603210897869-9QIDQX4X5T9UH7HMOGY1/CSE+Shifter+2.jpeg The Build Blog - Inner Space I had an epoxy sticker printed up with the CSE logo which replaced the Audi Sport logo on our shifter. Things are really coming together! https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1603140588478-L4QHQ7K79L2KR1OA1Z12/No+Console.jpg The Build Blog - Inner Space Notice that we removed the handbrake. Our car uses the same Brembo electric parking brakes that Tesla uses. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1603130234445-ARRWKQ4SAEHWJTADBU48/Wood+Console.jpg The Build Blog - Inner Space I fashioned a lower console out of plywood. BMW would have used plywood in 1974 so it’s fitting. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1603130254115-NN544J6ZVNXNNRNMJWCV/image-asset.jpeg The Build Blog - Inner Space I then shaped the edges and sanded it smooth. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1603130267022-VH2PIEFAPV4LNSLLKFE0/Upholstured+2.jpg The Build Blog - Inner Space I wrapped it in vinyl (I will have my leather guy get his hands on it eventually). https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1603211148368-9529DJ2HW6V01V6GOZ43/Finished+Console.jpg The Build Blog - Inner Space And I inserted a BMW cupholder and coin tray. I also attached an armrest with console. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1603140771440-58XOI8F1QUCZACZRJSBF/image-asset.jpeg The Build Blog - Inner Space I couldn’t resist taking a period-correct photo with some smokes. The car did come with three ashtrays from the factory after all. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1603145850633-QOOHXUJVJ54IZJAQWE0K/image-asset.jpeg The Build Blog - Inner Space These modern rear headrests came from the same BMW as our front seats. Notice the original blue vinyl on the rear seats in this shot. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1603145871652-YLRMD6ZQQ5YDIRXIPBQT/image-asset.jpeg The Build Blog - Inner Space After the seats were dyed black and a liberal amount of vinyl repair tape was applied. I think I can bring the car home looking like this. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1603029105590-WPBU9ZYFGU3JCK8XXWFU/Upper-Trunk-2.jpg The Build Blog - Inner Space https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1603029071130-PJE4TPFB25PXK00PWREQ/Trunk.png The Build Blog - Inner Space https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1603210445056-7BRXQLSU5TZVFMJ5NM0A/CSE+Interior+Complete.jpeg The Build Blog - Inner Space https://bmwcse.com/buildblog/no-more-tangles monthly 0.5 2020-10-19 https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1601223605506-2MVGMU4M1VCZSW5VHR5F/Get-the-Tangles-Out.jpg The Build Blog - No More Tangles https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1601402835100-H4XCCQ6EBZCHJ8L84N5P/CSE-Schematics-Small.jpg The Build Blog - No More Tangles https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1601224152311-5V1DGV42FAS19GF6RN6J/Front+Starting+2.jpg The Build Blog - No More Tangles The front fuse box is installed under the hood. I’m either carefully referencing the schematics, or watching Netflix on my laptop. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1601223999639-D65640I0H88NHQNUBW4V/Front+Complete+3.jpg The Build Blog - No More Tangles Fuses and Relays are all wired in, along with a custom thermostat module which turns on our radiator fans at 90 degrees. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1601223922401-13CMZ6W7PFHX7Z9WLVF5/Front+Complete+1.jpg The Build Blog - No More Tangles The box all closed up and ready to go. One clean wire loom runs past the large battery box under the hood. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1601225463311-N15E444HL2Z4Q5D9GOVM/Trunk+1.jpg The Build Blog - No More Tangles To the far right is our Tesla DC/DC transformer. It takes the 320 volts from the Tesla batteries and turns it into 12v to power all our automotive systems (think of it as our alternator). The transformer feeds a pair of 100 amp mega fuses. One of them runs directly to the BMW/Mini electric power steering pump. The other fuse feeds our three distributed fuse/relay boxes. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1601225589519-N6IMJNKCACD9AD8S1M80/Trunk+3.jpg The Build Blog - No More Tangles My motorcycle battery passes through a cutoff switch before entering the system. This switch will be accessible above the carpeted trunk floor. Since my clock and Raspberry Pi computer will always be running, I can disconnect if I am not driving the car for several days, or when I am working on the car. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1601225884106-4R4MRXSCGHOZ1VH8IK3V/Trunk+Complete+5.JPG The Build Blog - No More Tangles I then wired up the 057 Tesla controller and my parking brake controller. In case you missed it, the Tesla has no "Park" function, and hand brakes don't typically lock the wheels, so I am using the same Brembo electric parking brakes that Tesla (and many other cars) use. When I put the shifter in park, the parking brakes activate automatically. Everything was loomed nicely and it is all tested and stable. This is a huge improvement over our “before” photo. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1601226065891-D213ZAV2NRGLMJSUMWEB/Trunk+Floor+2.jpg The Build Blog - No More Tangles https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1601226205276-N77SEOGLN0G45MV6RZBJ/Upper-Trunk-2.jpg The Build Blog - No More Tangles Even though I worked hard to make the wiring look nice, it will all be hidden under our false trunk floor. These panels create a nice usable trunk space. This will all be carpeted in the next week. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1601226619676-GI3MFZMEAWL3NLCMQBKU/Console+1.jpg The Build Blog - No More Tangles I wanted to modify the way the console installs. I added brackets which would allow me to remove or adjust the console more easily in the future. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1601226947618-SGBZRSZZQW0OGXDO7A2A/Console-3-tall.jpg The Build Blog - No More Tangles I then added a plywood floor which I painted black. This will allow me to screw down the three computers which run our instrument cluster. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1601226693400-XDK8LC3ZL1V18VNJ5F7D/Console+4.jpg The Build Blog - No More Tangles The computers are in place. There is the Raspberry Pi unit which runs the digital display, then two Arduino computers to run the speedometer, fuel and temp gauges, and the odometer. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1601226720521-QRBR85XETZCWKSR7KJZO/Console+5.jpg The Build Blog - No More Tangles https://bmwcse.com/buildblog/add-a-dash-of-display monthly 0.5 2020-09-16 https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1600094323714-QQ2QM9YV73JBVO9IQF5I/Cluster-Done-Wide.jpg The Build Blog - Add a Dash of Display https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1600094613809-4O863L8HJC6JWPHS3PWZ/Generic+Screen.png The Build Blog - Add a Dash of Display https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1600096173930-TZCSCMATLWWS1VKJ5CUE/Speedo+Assembly+1.jpg The Build Blog - Add a Dash of Display Starting with a common stepper motor (this one is used in a lot of GM and other vehicles). I 3D printed an adaptor to convert the small output shaft to the original BMW shaft to which the needle attaches. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1600096207727-WP6DY75H46Y747Y9GO9D/Speedo+Assembly+2.jpg The Build Blog - Add a Dash of Display I soldered the stepper motor and it’s companion driver board onto a piece of project circuit board (which I first cut to shape). https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1600096387996-0QCFWO1H2QDL7I57Q1PK/Speedo+Assembly+3.jpg The Build Blog - Add a Dash of Display This old guy can’t solder anything without a magnifying glass and enough light to shine a football stadium. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1600096410271-MVD1C9LA9GX8AL3SIXQG/Speedo+Assembly+4.jpg The Build Blog - Add a Dash of Display The finished sub-assembly. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1600096450067-SKO8VM6WBJ5QHX8WV2VZ/Speedo+Assembly+5.jpg The Build Blog - Add a Dash of Display Don’t zoom in too closely, as the soldering looks nice from a distance. I bundled the wires into a clean loom which will exit the speedometer housing. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1600096483072-KCO5VODRRA8T28PTTBEO/Speedo+Assembly+6.jpg The Build Blog - Add a Dash of Display Looks clean from the front. Notice the smaller output shaft without our adaptor. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1600096523690-V6GQC964UGVUSA9XZHD0/Speedo+Assembly+7.jpg The Build Blog - Add a Dash of Display This is the back of the BMW speedometer with the old guts removed. Our unit is ready to install. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1600096553346-JISHFN9VLJGH14YGXW1R/Speedo+Assembly+8.jpg The Build Blog - Add a Dash of Display Our unit is now installed with a 3D printed housing (the 3D printing is a whole story in itself, but let’s just call it magic for now). Another plastic cap is installed before it goes into the Speedometer housing. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1600009204834-3SDAHN5WOE9FM8A9YRPW/Speedo+Gif.gif The Build Blog - Add a Dash of Display Once installed I press the needle on and you can see the motor controls the location based on my computer input. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1600097669499-DEEVW17JF9CGZKHDRVGW/Odometer+3.jpg The Build Blog - Add a Dash of Display Inside the speedo/odo housing (or “can” as I call it) I printed a mount to attach the stepper motor, which will drive the odometer mechanism. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1600097764497-UBZC2BP2Q36H9X3PWOLY/Odometer+Printing.jpg The Build Blog - Add a Dash of Display I learned how to 3D print, and I use a nice caliper to measure and create my designs. But that doesn’t mean that I get it right the first time. Luckily, these incremental rejects were printed with plant-based recyclable materials. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1600097715699-QNUGEQMEAXOHHZQTG67T/Odometer+4.jpg The Build Blog - Add a Dash of Display The stepper motor is now attached to the can. Not shown is a little adaptor I printed to connect the output shaft of our motor to the splined gear of the odometer. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1600097843888-0XKE0RVYDG0O63UT4I0H/Odometer+6.jpg The Build Blog - Add a Dash of Display There is a small driver board which runs the stepper motor. It sits behind the can. Notice the two loomed wires going to connectors. One is from our Speedometer assembly we already discussed, the other for the odometer. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1600097879040-K1O7SI1338W1475CIVZF/Odometer+7.jpg The Build Blog - Add a Dash of Display Then plastic housing covers the entire assembly. This unit is ready to install into the dash. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1600098437989-SDJHY2A0SIF9HX62TELU/Temp+Guts.JPG The Build Blog - Add a Dash of Display Thees gauges share the same can, which made fitting the stepper motors tricky. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1600098364789-X82U1Q0GHXDK34XU8X5R/Temp+Finished.JPG The Build Blog - Add a Dash of Display The motor is installed between two plastic pieces which create this assembly. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1600098475241-6165T1KGOWN70G0VF3FW/Temp+Testing.jpg The Build Blog - Add a Dash of Display This is what it looks like when we are figuring out how to get it to work. Wires everywhere. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1600100328561-LHHIEUDZHYJFRZZLCHB3/Stepper+Animation.GIF The Build Blog - Add a Dash of Display We now have computer control of these two gauges. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1600098873846-V2CUA3TURZKSZ2RWWU34/Display+1.jpg The Build Blog - Add a Dash of Display Here is our 5” round display which is fed by a ribbon cable from its driver board, which is fed by the Raspberry Pi via HDMI. The CAN bus '“hat” is sitting to the top right. This is all of the devices required to bring the display to life. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1600098849140-M0UVO0QUXY3AQZAJTEC8/Display+Mount+2.jpg The Build Blog - Add a Dash of Display The display is mounted to the back of the instrument cluster through a lot of 3D printing. The display is secured with the base layer, then the driver board to the back of that. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1599937181231-7N5SBB3KDKQCWBN0Y5R3/IMG_3131.jpg The Build Blog - Add a Dash of Display https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1599936991356-KQKRBLK6KNQ1BIX7S1QW/Cluster+1.jpg The Build Blog - Add a Dash of Display https://bmwcse.com/buildblog/2020/6/19/mint-green-shark monthly 0.5 2020-07-22 https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1595388608980-JUITZOTR787OQVHVUX8O/Green+Shark.jpg The Build Blog - Mint Green Shark https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1595388241103-D2MSFN6T8ZK1KXAKN22Z/Steel+Shark.jpg The Build Blog - Mint Green Shark Here is what the couple looked like during our first drives around the building. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1595178890746-IKKTIZ7H2AT6DM2ZXHPZ/Primer+Sprayed.jpg The Build Blog - Mint Green Shark We sprayed the car with the green primer. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1595177482584-JFPVBOA4NJZDLOUKRAUO/Mint+Green+Shark.jpg The Build Blog - Mint Green Shark After most of the exterior trim was installed. It’s looking like a presentable car. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1595178115539-9O1JPRFXTQ7FYIXEFQ65/Weld+In+Doorlocks.jpg The Build Blog - Mint Green Shark Tyler fills in the key lock hole. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1595178129068-CQA21WGFXDYUXXY4288T/Paint+Doorlocks.jpg The Build Blog - Mint Green Shark He smoothed it out. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1595178157705-6VVFRL9OMD4NRK4SAUST/Finished+Doorlocks.jpg The Build Blog - Mint Green Shark And we’ve got a clean new look. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1595178778985-E5W8IPJJDVQG8ZKIM9JT/Gas+Struts.jpg The Build Blog - Mint Green Shark We implemented modern gas struts to save weight from the original and very heavy hood support mechanism. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1595178327068-ZBOGQPMRG57Y2BQCR8GG/Hood+Roundel.jpg The Build Blog - Mint Green Shark The original and very weathered BMW Roundel looks fantastic against the matte green finish. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1595178501277-9MGPW3ICYU141DUHQIYV/Tesla+Trim.jpg The Build Blog - Mint Green Shark A little fun with the license plate frame. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1595178380111-R6KBPJE3HUCCUDDT33GS/Front+Bumper.jpg The Build Blog - Mint Green Shark https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1595281706944-6V831LT3AG51C0U0WUS7/Green+Coupe.jpg The Build Blog - Mint Green Shark https://bmwcse.com/buildblog/2020/3/8/shifting-gears monthly 0.5 2020-09-15 https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1583087162098-IZFMOY90R1R5X1ZB32KV/Audi-Shifter.png The Build Blog - Shifting Gears https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1583088058713-4OAD8NBC6CBJIN5UE5QH/IMG_1760.jpg The Build Blog - Shifting Gears I soldered new leads to the solenoid and the release button microswitch. Automotive wire wrap was then used to keep things clean. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1583844036273-UYRLL9X15OI5KPXAXBQT/Switches.png The Build Blog - Shifting Gears Here are our first two microswitches going into place. In this photo the unit is in Park position. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1583704026982-IR563UITLQBL1S3PYHU1/Shifter+Assembly.png The Build Blog - Shifting Gears The shifter is all wired up and a custom cover is installed to protect the mechanisms. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1583844175866-XR3V5PXY2TS2COXB6LRG/Welding+it+in.png The Build Blog - Shifting Gears With the shifter held in place Tyler gets busy welding the mounting brackets below. The unit is easily removable for service. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1583705541005-5WMZCUMV579HHR9ZU4VS/Shifter+Installed.png The Build Blog - Shifting Gears The shifter looks right at home in the console. We will fit a proper leather boot and even fabricate a wooden shift knob when we get to the interior finish of the car. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1583705577478-95E04I10E7ORL25SSOUG/Old+Control+Panel.png The Build Blog - Shifting Gears This marks the end of our temporary “space ship” control panel. We’ve now automated every switch and button required to operate the car without it, but we’ll certainly hang onto her as a shop decoration. https://bmwcse.com/buildblog/2020/1/4/we-flew-the-coupe monthly 0.5 2020-01-17 https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1578930578524-M4N32G6K2G6B84E150M7/First+Drive+Smiles.jpg The Build Blog - We Flew The Coupe! https://bmwcse.com/buildblog/2020/1/2/thats-the-brakes monthly 0.5 2020-01-13 https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1578791017099-A700TYPSEPPFE55T4F0X/vw-porsche-mag.jpg The Build Blog - That's the Brakes https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1578792944156-XDBDBBQFXWBCVJTRON6O/Wilwood+Items.jpg The Build Blog - That's the Brakes The calipers arrived looking very impressive, but I thought that we should add a bit of personality to them. So off to the powder coater they went. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1578792072982-5IPCQD6PB42WZVEG55AQ/Front-brakes.jpg The Build Blog - That's the Brakes They returned in dramatic orange. The front setup is looking good here. The rotors are over an inch larger than stock front and rear. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1578792086322-ZHCN05IT5GJEJHOQ1S3Q/rear-Brakes.jpg The Build Blog - That's the Brakes In the rear, Brett did some major mods to the trailing arms. Cutting a notch, then welding a custom bracket to mount the calipers. It was all worth it to match the angle of the fronts. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1578795228026-QG5G0835ZN3LW8S5AGXA/Inner+Front+Brakes.jpg The Build Blog - That's the Brakes Inside the front fenders, things are looking clean. Wilwood stainless steel flexible hoses on all corners (We haven’t talked about our coilover suspension here yet). https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1578936762935-PPA8FK8QWY9HJ26XXKRH/Master+Cylinder-2.jpg The Build Blog - That's the Brakes Looking up into our transmission tunnel. Master cylinder, adjustable front-rear proportion valve, then all new brake lines to each corner. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1578933931282-Z4Q8GGWRNYUG7PD9CUQN/All+Brakes+on+car.jpeg The Build Blog - That's the Brakes When all was said and done we have serious stopping power with a touch of personality. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1578238816338-5F0TG82JHAPPOR1Q0T1A/Worm+Drive+Calcs.png The Build Blog - That's the Brakes Note: I have no idea if this is the actual equation, but it looks impressive. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1578794299842-QT9FZ91GPLX7QSLWRSJ7/custom+rear+bracket.JPG The Build Blog - That's the Brakes Tyler built some nice mounting plates, which bolt to the original threaded BMW caliper holes. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1578795458408-WCEU4DVGECFVZLGH7YE6/Rear+Brembos.jpg The Build Blog - That's the Brakes The installed Brembo electric parking brake from the front. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1578795118227-37WL7IQHTJ6LI1AF444N/Brembo+Wiring.jpg The Build Blog - That's the Brakes The wiring runs through retainer brackets to protect them from pinching or rubbing anything dangerous. https://bmwcse.com/buildblog/2019/12/19/untethered monthly 0.5 2020-03-08 https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1577752506249-G8MAB120VU0Q6BIV7VF3/Exposed+Trunk.jpg The Build Blog - Untethered https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1577754592480-7OGXLL4SMQ9OAL5DWYWE/8-Upper+Floor.JPG The Build Blog - Untethered First we install the upper trunk floor. We had grand ideas of this section being plexiglass so we could show off the Tesla motor from up above. But batteries need to be installed into this area, so we put in a steel floor. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1577753777774-90GQFV1207YPYFU9QXDN/1-Pattern.JPG The Build Blog - Untethered For the lower trunk floor Tyler started with creating a cardboard template of the trunk shape. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1577753852251-QDSO4ZR4Y355WBM6192Y/2-Trace.JPG The Build Blog - Untethered He then traced it to a sheet of steel, then cut the shape. Just like in 2nd grade art class, but don’t tell that to Tyler. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1577753873691-03Q6VBPKDTGD2IKGKO1E/3-Pound.JPG The Build Blog - Untethered Tyler created ribs using a hammer and chisel. Ribs add rigidity and strength to an otherwise flimsy piece of sheet metal. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1577753900087-R07EVMM0JTYW5JKD554T/4-Floor.JPG The Build Blog - Untethered Now it’s starting to look like a professional car part. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1577754333606-5XRZW00GP9JI68HI6WH8/5-Floor+in.JPG The Build Blog - Untethered She drops beautifully into the car to create a clean floor. The sections without ribs are where our devices will be mounted. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1577755292518-BE362AKH8Z94NRBO7STC/6-Vertical.JPG The Build Blog - Untethered Next up is the vertical piece that connects the upper and lower trunk floors. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1577755121810-NPNKN10A7G3G5L14DPS6/6.5+Floor.JPG The Build Blog - Untethered The panel fits nicely and is ready to be welded in place. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1577755253628-GOOMNV2E7NU0ENYQIZ4N/7-Frame.JPG The Build Blog - Untethered But first we add square tube supports which will support the weight of the equipment, while also reinforcing the rear of the car. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1577754629323-IJPS00DDR03J4ZIE9Y45/9-Trunk+Done.JPG The Build Blog - Untethered We now have a complete enclosed trunk. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1577752205141-3DTI0A4M2UGUWJAJE744/Trunk+Bottom.jpg The Build Blog - Untethered Here is the trunk from under the car. The motor now feels like it has a home, rather than hanging there exposed. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1577902699011-GJL5SQ55LT35J55HCMCJ/Trunk-Equipment.jpg The Build Blog - Untethered https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1577979109553-XU5M4HIS3CSI9PPQAGQ2/Cockpit.jpg The Build Blog - Untethered https://bmwcse.com/buildblog/2019/11/8/battery-box monthly 0.5 2019-12-31 https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1576347408904-UK19ADDNQNF49FBJN45O/Wide-Open-Bay.jpg The Build Blog - Battery Box https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1575729833755-YT75QSG8KNWLXXLK2P7Z/Sheet-Aluminum.jpg The Build Blog - Battery Box Aluminum cuts smooth and easy on a tablesaw as if it were a piece of thin plywood. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1575731723813-1PM8I4FFFTDB190VGHYS/Welding-Aluminum.jpg The Build Blog - Battery Box Tyler is a master with the tig welder. I learned a lot about welding aluminum on this project. Very tedious. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1575729851839-QQ34HLX2U2791PQ02AQ3/Bottom-of-Box.jpg The Build Blog - Battery Box In between the car’s frame rails we are able to squeeze in a lower section holding two battery modules. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1575745600991-ZOQI7FDF99TJ5ZMA4SFZ/Lower-Box-Done.jpg The Build Blog - Battery Box Here is our lower section complete with the modules slid into their tracks. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1575745569153-D1U9QK2R8N0SBMP7FXBX/Empty-Box.jpg The Build Blog - Battery Box The full box is starting to take shape. We are able to get 9 modules across in the main body of the box. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1575730243913-KOTXIL6UTXGH04XRNZXW/Box-Continues.jpg The Build Blog - Battery Box Here you can see the 3 tiers of the box: 2 on the bottom, 9 across the center and 1 more on top. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1575731158029-TEHEXKBIDV18RC9DFG47/Copper-Bus.jpg The Build Blog - Battery Box Here’s an example of a custom bus bar which connects the two bottom modules in the chain. It looks rough now but will be plated and dipped in orange to look like the ones in the next photo. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1575731183972-BC0YVF5D6D2W29FWM3PI/Modules-Complete.jpg The Build Blog - Battery Box This photo shows the 9 modules across looking nice with custom bus bars. Also the cable running to the top module and down to the junction box. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1575731259291-4XMLEKVO9XAPO3GG3DX8/Bolting-it-in.jpg The Build Blog - Battery Box Each corner of the box has brackets to secure it to the car. The corners of the box are steel reinforced on the inside for this purpose and also for living the box. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1575731207384-ERA7GSUB9BS1KHVWA7L9/Box-Complete-in-Car.jpg The Build Blog - Battery Box A little bit of logo work and the box looks very nice in the car. She comes in around 750 lbs. That’s about what the stock drive train and accessories, so the car is comfortable with the weight. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1575731284549-I2JGHM8YCL7ETOZOO8Q9/Under-Car.jpg The Build Blog - Battery Box Very tidy underneath. You can see that we used every inch of space. If you look close you can see inside the junction box. A fuse is inserted as well. Any electrical short behind the box will blow the fuse - not the modules. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1575731746333-9GS6JLI5VRU7RC9TLV0N/Rear-Modules.jpg The Build Blog - Battery Box Finally, we installed the 2 last modules in the upper trunk area. This leaves plenty of trunk space. There’s even room for one more module if we ever get the desire for “more”. https://bmwcse.com/buildblog/2019/9/19/turn-the-brakes-around monthly 0.5 2020-10-19 https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1575679490741-Q4UUSXXW4RQCXB39X0L1/Stock-Brake-Setup.jpg The Build Blog - Turn the Brakes Around https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1575678199695-WCD8PG778MUSEVGY5XJS/Child-Labor.jpg The Build Blog - Turn the Brakes Around https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1575678226321-ZXQ67AH06OFPQ3T4D1QK/Floor-Cut-Open.jpg The Build Blog - Turn the Brakes Around https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1575678242301-TI4RSAKNPVO4ZZ72F841/Floor-Finished.jpg The Build Blog - Turn the Brakes Around https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1575681377962-FCYMY1S6PZ3WFWYMPLA5/Booster+Installed.JPG The Build Blog - Turn the Brakes Around https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1575682733140-WUM53IW9J8C8YS3EOCU3/Cutting-Greg.jpg The Build Blog - Turn the Brakes Around Brett started with a piece of 3/4” inch steel plate and a plasma torch. He had made a guide and could just ride the torch along for a perfect cut. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1575682762993-ILLUF88XXUCLRJY3TD3J/Greg-Rough.jpg The Build Blog - Turn the Brakes Around The plasma torch provides some terrific looking metal artifacts. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1575682783836-BOWCCJIK85EK64RTP6PJ/Greg-Bending.jpg The Build Blog - Turn the Brakes Around We heated Greg up a few hundred degrees where he gave up his strength and we could twist him into the compound shape we needed. Once the shape was achieved, we evenly heated Greg up to get his particles all in harmony for strength. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1575682852550-4DTCZRP1ZG7V9OOK1W9S/Greg+Professor.JPG The Build Blog - Turn the Brakes Around https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1575682809111-7FNCQ0CZTX53T4BU7TAP/Greg-Installed-jpg The Build Blog - Turn the Brakes Around https://bmwcse.com/buildblog/2019/7/25/a-seat-in-first-class monthly 0.5 2019-08-05 https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1564523347592-1N6N9FBRT3V8Y9LEI4GS/Factory-Seats.jpg The Build Blog - A Seat in First Class Some of the prettiest classic seats you have ever seen. (Photo credit unknown) https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1564583464458-61HLPFG1CKPUELLMB0FO/Hammer-and-Dolly.jpg The Build Blog - A Seat in First Class Tyler hamming the floor from up top while Brett holds the Dolly with a rod to the floor. I would have helped as well, but I was busy shooting video. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1564612721334-6P1UGQ0F2WX9CTMUALZ0/Seat+Plating+2.jpg The Build Blog - A Seat in First Class Steel plates were fabricated to mate with the bottom of the floors. The seats will bolt through to cap nuts welded to these plates. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1564583656725-5OSIU274PLGEASTA8HNY/Floor-Risers.jpg The Build Blog - A Seat in First Class Our floor risers create a smooth surface for the seat rails to rest on. They will be further welded once all fitting is finalized. Notice how BMW uses two rear bolts on the shoulder belt side of the seat. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1564670891640-8JNTDK6OWR7TEF7MHZF2/New+Seats+2.JPG The Build Blog - A Seat in First Class https://bmwcse.com/buildblog/2019/6/24/just-spinning-our-wheels monthly 0.5 2020-01-03 https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1564236885946-U2IDFIW1D2ZAJWNSYBF9/Subframe-Mount-2.jpg The Build Blog - We’re Just Spinning our Wheels Looking front to rear, the subframe extension extends forward. Notice the Tesla unit in the rear, at the bottom of the photo. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1564237204648-49796YTXJ5GYA8V5CDJT/Frankenstein-Axle.jpg The Build Blog - We’re Just Spinning our Wheels Beautifully crafted axles. They are completely new but the far right section which was out of a Tesla. The left end bolts to the BMW wheel hub and the right spindled end inserts into the Tesla drive unit. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1564237762815-T3I47PFIUJC4XGVOSDRP/Control+Panel.JPG The Build Blog - We’re Just Spinning our Wheels Our Jetson’s-inspired control panel, used for our early testing. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1564238069820-Z2U5TAVCTGZX2L23840Q/Tesla-Drive-System.jpg The Build Blog - We’re Just Spinning our Wheels Here is our collection of control equipment L-R. (offscreen) our vintage control panel, 12v battery to power the three computers, 057 Tesla controller, precharge system including control board, resistor, and high voltage contractors, and accelerator pedal. https://bmwcse.com/buildblog/2019/5/29/we-will-rocker-you monthly 0.5 2019-07-28 https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1563937179283-Z99KAG590RYQK0B9G6BH/Bad-Rockers.jpg The Build Blog - We Will Rocker You https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1563937918886-1X1QKQ0ESL9ZRLVJQRW2/Rocker-Cut-out.jpg The Build Blog - We Will Rocker You We began by carefully cutting the rot out layer by layer back to good steel. This photo shows what was left once the rot was removed. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1563939422970-ZICPN82WN2WR2UVPQSS3/Layer-1.jpg The Build Blog - We Will Rocker You Tyler then fabricated a section to rebuild the first layer. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1563938545032-DYI7F3DMMZ80VVLZ9379/Layer-2.jpg The Build Blog - We Will Rocker You We then started fabricating the next layers. We also rebuilt the lift point pockets. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1563939330108-3B6SDQ53338II2EEGQXD/Layer-3.jpg The Build Blog - We Will Rocker You More fabricating and more welding… https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1563939556461-6P7NWLDC8LJBSUBWDGOF/Front-Rocker-1.jpg The Build Blog - We Will Rocker You https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1563940383859-261A11FBOPPUH8Q4NMPU/Front-Rocker-2b.jpg The Build Blog - We Will Rocker You Figuring out what was supposed to be going on was the biggest challenge. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1563940068486-RRCP8YZD4135GLYT4L9V/Front-Rocker-3.jpg The Build Blog - We Will Rocker You We are not against buying sections of metal when it makes sense. More than happy to not fabricate this complicated little guy. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1563941162007-EAHLQ7K3LSCIO1H8PEGG/Finished-Rockers.jpg The Build Blog - We Will Rocker You https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1563977661964-UPL4QVISQAMM28MR26WF/Floor-1.jpg The Build Blog - We Will Rocker You https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1563977679969-U6N7CS6IU8W7CT0W867Z/Floor-2.jpg The Build Blog - We Will Rocker You https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1563977694889-ZIUJLX97B3HKHFCF93E7/Floor-3.jpg The Build Blog - We Will Rocker You https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1563978543907-O6GDPIFE1RZD6833VE6F/Instagram.png The Build Blog - We Will Rocker You https://bmwcse.com/buildblog/2019/4/25/steering-committee monthly 0.5 2019-05-03 https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1556906491110-M1C4RKVOKRXVPVWHL2XL/Cutting-Mounts.gif The Build Blog - Steering Committee We started by cutting away a handful of motor and steering mounts from our subframe. Cutting away stuff is usually my favorite part of the project. Brett here is having a dandy time with the plasma torch. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1556917376248-AMS7UJ9S4M387JGM8EE4/Rack-in-place.jpg The Build Blog - Steering Committee We test fitted our new rack in position using a series of construction clamps. They did the job just fine. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1556922270869-HU7NKA7R74OGLFJTJV6B/Brackets.jpg The Build Blog - Steering Committee We cut some funny shaped sections of steel to make some mounts… https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1556907498685-CHVME8F165IOIZ6GWJC1/Steering-Rack.jpg The Build Blog - Steering Committee Then we got the rack tack welded in. Things look good in there. Nice and compact and low in the compartment. We will finish the welding and clean everything up after a bit more testing. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1556918317453-KE5TNQU0IE081N02TKJH/Steering-Column.jpg The Build Blog - Steering Committee Our E46 steering column is fitted into the dash with a bit of customization to the mounting areas. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1556919685080-MIW12BD7S28FUOKR6049/Linkage-Tall.jpg The Build Blog - Steering Committee Here’s our Frankenstein steering linkage. Starts as a BMW on top, then mates to VW linkage on bottom to connect to the steering rack. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1556919801063-FRVJMTEQDPI1DDXA635G/Linkage-Connected-2.jpg The Build Blog - Steering Committee A lot of cleanup yet to be done on the firewall, but the linkage is tidy and works wonderfully. https://bmwcse.com/buildblog/2019/3/17/junk-in-the-trunk monthly 0.5 2019-03-18 https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1552860329143-UT3XGG7MPHHP5KUQQK5O/Trunk-Cut-Out.gif The Build Blog - Junk in the Trunk https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1552860789946-2A3MPKCFVG7ZR6Z8QS9S/1-Tesla-Stand.gif The Build Blog - Junk in the Trunk Here’s our Tesla motor stand. I am going to reach out to Elon to see if he wants to put an order in for several:) https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1552860804825-SXXKFBPE8WN5NCUN1YEW/Tesla-Lift-2.gif The Build Blog - Junk in the Trunk A forklift is the closest thing we have to an engine hoist, so here we go. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1552860840831-VC7NJXL0SPJUOQ4FADFK/Tesla-Stand-3.gif The Build Blog - Junk in the Trunk The unit feels secure in its temporary home. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1552860488724-P2AGK2JOQ377IIT7X4CT/Tesla+Unit+in+Position The Build Blog - Junk in the Trunk https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1552861235897-MCTUOYPV1YKW7XUL6YY9/12-Welding-Plates.gif The Build Blog - Junk in the Trunk We plated the front and rear of the wheel well to distribute the loads and to give us something to attach to. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1552861252469-Y5YPWL6AX36FCZW4N4MR/13-Welding-Plates-2.gif The Build Blog - Junk in the Trunk Brett welds in the horizontal plating, which will support our front mount. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1552862750140-1TK1C82QH6UKW08GT17B/Fabricating-Front-Mount.gif The Build Blog - Junk in the Trunk The front mount had the trickiest shape to it and required some bending of the center plate. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1552862577637-4GAO0LJ1T390397Q6SSC/18-Front-Mount-Completed.gif The Build Blog - Junk in the Trunk The front mount welded into the car. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1552863129965-88R018E4QZPKBOU5AJ6W/19-Installing-Plates.gif The Build Blog - Junk in the Trunk We created a side mount plate with a compound bend by notching, then smoothing out. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1552862646537-OJ46WG3UD3T7IAH67BEM/Side-Mount.gif The Build Blog - Junk in the Trunk Welding the side mount sections to our plate. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1552863385559-029X5Y6OX16KE6T36KX7/24-Rear-Mount-Complete.gif The Build Blog - Junk in the Trunk The rear mount suspends from a beam which spans between the wheel wells. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1552863369729-5XZSH2R4IBN9FCG7SZX8/23-Rear-Mount-Gussets.gif The Build Blog - Junk in the Trunk Reinforcing the hanging points with gussets. It was just an opportunity to take a photo through the taillight hole. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1552867660874-U1JLLK39CIQX3P7QEIY4/Mounts+done+and+primed.gif The Build Blog - Junk in the Trunk With the welding done, we cleaned up any rough edges and applied etching primer to everything. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1552868294957-CIW64T5T85D9SWFUKN5M/Tesla-In-the-Coupe.gif The Build Blog - Junk in the Trunk Finally the drive unit is hanging in it’s final home! We strapped the front of the car down to the lift just in case things got a little back-heavy:) https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1552868148042-D54VW57EI5Y76MV5B79U/Tesla-in-the-Coupe-2.gif The Build Blog - Junk in the Trunk https://bmwcse.com/buildblog/2019/3/8/here-comes-the-sunroof monthly 0.5 2021-04-06 https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1552090950005-CI9VX36BLWX03IWUWZEI/Functioning-Drains.gif The Build Blog - Here Comes the Sunroof https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1552092910301-AJPZTCY15R63S2QA0Y8V/Sunroof-Roof.gif The Build Blog - Here Comes the Sunroof Here is the roof from inside the car. Rust on all four sides. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1552093011920-D4YZAC701DWQCW6HC23T/Sunroof-Frame-Rusted.gif The Build Blog - Here Comes the Sunroof The damage to the frame (the sunroof track) was even worse than the roof itself. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1552093066780-ABJJR9RF9D85IY8NEK1Z/New-Roof-1.gif The Build Blog - Here Comes the Sunroof Trace the sunroof hole and prep it for cutting. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1552093109052-HN78PS45EWBL77FF0T75/New-Roof-Cutting.gif The Build Blog - Here Comes the Sunroof Cut along the line- this part seems a lot like elementary school art class but with steel. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1552093086944-MNO5H8R6QPIHEI2SGHF0/New-Roof-Bending.gif The Build Blog - Here Comes the Sunroof Begin the process of bending the edges to form our thick and smooth final edge. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1552093164417-1P783J42BC48LT9D9DBE/New-Roof-Bending-Corners.gif The Build Blog - Here Comes the Sunroof Continue the bending and shaping process with the panel setting on the car. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1552093187246-MCAIZOWUM1QBQA7GNKSY/New-Roof-Placed.gif The Build Blog - Here Comes the Sunroof Finally we have a panel which is looking like a final product. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1552093247947-LEIW9DSLPX0R1M6SVQDT/New-Roof-Smoothing.gif The Build Blog - Here Comes the Sunroof Weld the piece in, then smoothing, smoothing, smoothing. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1552100727538-FSPEB8KXEUEA0Y4CVNX1/New-Roof-Done.gif The Build Blog - Here Comes the Sunroof https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1552093793733-HKQDSV33TMOAA0PEQIC2/Sunroof-Frame-Jig.gif The Build Blog - Here Comes the Sunroof Our frame attached to the jig. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1552100143912-MITXF39TUTTQJ0J899TZ/Frame-Work.gif The Build Blog - Here Comes the Sunroof With the frame on the jig we can cut out sections and start replacing them. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1552093513617-F2RV14LIR5PXGMEHG97Y/Sunroof-Frame-Fabrication.gif The Build Blog - Here Comes the Sunroof Tyler is a patient craftsman. Give him some steel and some tools and he can turn out just about anything. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1552093489179-KU7WELIG4SM3RU1KFBLG/Sunroof-Frame-Cutting.gif The Build Blog - Here Comes the Sunroof Here’s a fun, rusty rounded corner, https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1552093536024-IZEXGJ4N9PQP020GQBZY/Sunroof-Frame-Repair.gif The Build Blog - Here Comes the Sunroof And here’s the new replacement piece all clean and tidy. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1552093881804-0YA2H6PURIJ1UJLR3VOU/Sunroof-New-Frame.gif The Build Blog - Here Comes the Sunroof All the new sections welded and smoothed into the frame. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1552093600332-TQM7XXKPWUQVEERS4ZJP/Sunroof-Track-Coated.gif The Build Blog - Here Comes the Sunroof The restored frame receives a fresh black coating. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1552093658922-NKUSHTBHBZ4F9JW96LBO/Tyler-Sunroof.gif The Build Blog - Here Comes the Sunroof Installing the frame back into the coupe. Tyler loves crawling around grinding things in the car. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1552093619338-CKHFAI8WJMJDNAKZOT9R/Sunroof-Track-In.gif The Build Blog - Here Comes the Sunroof It’s looking good from up above. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1552093363817-T3C4GN2W4UTW69ZU8SPF/Sunroof-In.gif The Build Blog - Here Comes the Sunroof https://bmwcse.com/buildblog/2019/1/28/cut-weld-smooth-repeat monthly 0.5 2019-02-05 https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1549212584750-S9FD9RGVSNTSTNEKTJIZ/Trunk+Rust+Repair+1.JPG The Build Blog - Cut, Weld, Smooth, Repeat. Cut out the cancer… https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1549212629482-GZ5D4A5CURFUY0WHQYHX/Trunk+Rust+Repair+2.JPG The Build Blog - Cut, Weld, Smooth, Repeat. Weld in a fresh section… https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1549212654123-WW6O6UVUI9QCLZPF71ES/Trunk+Rust+Repair+3.JPG The Build Blog - Cut, Weld, Smooth, Repeat. Then smooth it out. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1549323079989-9CW6MP7P673I9RKG2OQ5/Old-Frame-Rail-Square.gif The Build Blog - Cut, Weld, Smooth, Repeat. Remember this photo from a few posts back? https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1549323113878-Z8BCUWIA8JPO1VR3WCF0/New+Frame-Rail-Square.gif The Build Blog - Cut, Weld, Smooth, Repeat. Looking a lot better now. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1549213775451-YBT2DV41CN2VGA9KPK58/Tesla-Drive-Unit.gif The Build Blog - Cut, Weld, Smooth, Repeat. https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1549213271186-JCKO9WE8ZB415DE55H23/Pallet-o-Batteries.gif The Build Blog - Cut, Weld, Smooth, Repeat. https://bmwcse.com/buildblog/2018/12/31/swiss-cheese-and-the-rebar-method monthly 0.5 2018-12-31 https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1546281993893-PVIWXGJ4HT2F8O3E7PRO/Blasted-Car.gif The Build Blog - Swiss Cheese and the Rebar Method https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1546286004198-WSAS7QCOHN21AMTK8SV8/Front-Blasted.gif The Build Blog - Swiss Cheese and the Rebar Method https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1546286018919-69JH295ROA52OY87G9EN/image-asset.gif The Build Blog - Swiss Cheese and the Rebar Method https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1546285246784-53GECL4GGYFZXHD5X7FF/Rebar-Method.gif The Build Blog - Swiss Cheese and the Rebar Method https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1546290543740-6ICX5V7MSBG5QGMJTNLQ/Batteries-Mock.gif The Build Blog - Swiss Cheese and the Rebar Method https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1546292166052-FII3IVX63H63RRKZXQ4M/Raspberry_Pi.png The Build Blog - Swiss Cheese and the Rebar Method https://bmwcse.com/buildblog/2018/12/8/strip-club monthly 0.5 2019-08-03 https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1544297568833-S3SDSIPAZOTFSRMTYEQ4/Man-Under-Dash.gif The Build Blog - Strip Club https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1544306531122-2QBGTEH5X7BKZFEL1LD3/inside.jpg The Build Blog - Strip Club https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1544297625655-TNX5CS9C0F1DJK71RKIP/Stripped+from+Front.gif The Build Blog - Strip Club https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1544297678633-JZ2ZSHCXVRPOZSDG2N3E/Leaving-the-Shop.gif The Build Blog - Strip Club https://bmwcse.com/buildblog/2018/10/19/out-with-the-old monthly 0.5 2018-12-13 https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1540045489981-YV4G47SI6MRDQT6H0NDW/2002s.jpg The Build Blog - Out with the Old https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1540045474874-SM2PNBCU5FPURDPANTLF/desert.jpg The Build Blog - Out with the Old https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1544307348404-QU4AN8NKL4UXAECRF2FI/BMW-Overhead-Working.jpeg The Build Blog - Out with the Old https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1540046441259-PFOF7RSS6064GB7OXI5D/Engine-Going.jpg The Build Blog - Out with the Old https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1540069834998-C6N067ZBHCI49177OTMR/steering-rod.jpg The Build Blog - Out with the Old https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1540047850394-W0JE4EMID8XWDJX2BMIV/No-Drive-Train.jpg The Build Blog - Out with the Old https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1540048124181-96CI8K4P7N14J6M0GSE1/BMW-Motor.jpg The Build Blog - Out with the Old https://bmwcse.com/buildblog/2018/10/12/setting-up-shop monthly 0.5 2018-10-15 https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1539386763173-07KHP1NI5CVBQGGQSFZR/Lift.jpg The Build Blog - Setting up Shop https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1539628284606-I6VPECI3E6LAWCEMJ0IQ/Rust-1.jpg The Build Blog - Setting up Shop https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1539386300638-1N884S1C8JV2U3EISYL0/Keep+Going.jpeg The Build Blog - Setting up Shop https://bmwcse.com/buildblog/2018/9/21/weighing-in monthly 0.5 2018-09-30 https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1538323189287-OZQGW7YCU52LDQM80LHB/weighing-in.png The Build Blog - Weighing In https://images.squarespace-cdn.com/content/v1/5b6635c2a9e02808a74be188/1538322359104-FNJXA14KVJYTL1FMECRC/Scales.png The Build Blog - 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