Looking for feedback, comments, and opinions - good or bad, I can take it. :_paranoid :lol: The easy way would be to stick a 6" dropped straight axle under the front and call it a day, but I want to see if I can make it look kind of vintage with IFS for competent autocrossing. My solution is to cover the a-rms with suspension fairings, like an old LSR or dirt track car might have had. I did this quick Photoshop rendering to see if I should pursue the idea in real life, or look for a better plan. What do you think?
http://toddperkinsdesign.com/images/...ms/art/068.jpg
The gap lines on either side of the grille are for headlight doors. They're that tall because the lights inside will likely be Woodlites.

I did CAD models for the hood and suspension fairings, then cut them from blue board (polystyrene) foam (from Lowe's). I had already split the models into sections to eliminate undercuts, and the CAM software slices those sections to match the thickness of the material you're using (1.5" in this case). I left these models a little on the rough side because I want to finish them by hand, to fine-tune the shapes. The CAD/CAM process gives me perfect mirror images to work off, from side A to side B, with lower blood pressure. :)
http://toddperkinsdesign.com/images/...ldpics/153.jpg
http://toddperkinsdesign.com/images/...ldpics/154.jpg

Next, I have to carve out enough foam to get the fairings in place, then use canned foam to glue them to the hood and track nose, plus fill the voids. The front clip will be a one-piece lift-off deal, with an opening hood panel to display the motor.

Very interesting project.:thumbsup: Scott

Thanks Scott! :)

http://toddperkinsdesign.com/images/...ldpics/155.jpg
One step closer. A little carving and sanding, then some 'glass lay-up, and I will have a one-piece lift-off front clip to hide the IFS.

We were invited to bring the Inhaler (as a work in progress) to a "Green Bag Lunch" Earth Day event at Ohio State's Center for Automotive Research (CAR) facility. After a video presentation and brief talk by the director, they gave a tour of the facility. The Inhaler was just behind the World's Fastest Electric Vehicle, the Buckeye Bullet 2.5 (BB2.5) (320mph/307.666mph int'l record), and we were given the floor to present it directly after BB2.5. It was well-received, and we have an offer of support from CAR. :)
http://toddperkinsdesign.com/images/...ldpics/156.jpg
http://toddperkinsdesign.com/images/...ldpics/157.jpg
http://toddperkinsdesign.com/images/...ldpics/158.jpg
http://toddperkinsdesign.com/images/...ldpics/159.jpg
http://toddperkinsdesign.com/images/...ldpics/160.jpg

It does another Earth Day event tomorrow, a tech event called Innovate Columbus Wednesday, and a Science Fair at COSI (Center of Science and Industry) next Saturday. We also just received an email suggesting that we have it on display in the lobby at another tech event on the 5th.

I feel like the parent of a teenager. The little snot rips and runs so much I'm having a hard time finding time to get any work done on it! :lol:

Freakin' thing spent so much time going from event to event I couldn't work on it! :D It's finally been back at the shop, without scheduled appearances looming overhead, and I am getting my gears spinning again. First, I needed to finish the CAD work for the front clip, so I can get it out of foam and into fiberglass soon. This is the grille area.
http://toddperkinsdesign.com/images/...ms/art/076.jpg
http://toddperkinsdesign.com/images/...ms/art/077.jpg
These pieces are ready for CNC work. The actual nose will be cut in foam and grafted into what's already there. The trim ring will be cast in aluminum, so I am looking into having it printed instead of cut to save time. The "grille" panel will be cut in wood or resin to create a plug to pull a mold for carbon fiber lay-up. The first rendering shows the grille sitting on the surface of the nose because the foam section is modeled undersize for moldless composite lay-up over foam, and the grille and trim ring are to spec for plug construction. I hadn't created the mounting flange for the trim ring yet either. The grille assembly will be recessed into the body about .125" - about the amount it's over the surface at its highest point (in the first rendering, side view).

The hole is the intake for the forced-air system. It will have a black mesh screen with my batwing "T" logo (without text) embossed into the screen. The logo will be cut or cast in some metal, and I will probably do CAD/CNC dies to stamp the screen to fit and accept the logo.

Working on the windshield frame now. It's probably going to be pretty involved, and maybe another candidate for printing. So far, I have about a 30-degree layback, and 20-degree flare-out at the top. Should be pretty wicked. :yes:

Looking good Todd.
I like the nose... however (imo) your may consider reshaping the rear to match that cool new front end

Awesome CAD work! What program?

Thanks! I know people always say this, but I really have been meaning to stop by. My schedule has just been so crazy, when I have free time I'm usually vegged out in front of the laptop and TV. How's life treatin' ya? :)

When you say reshape the rear, do you mean the bed? There are some tricks up my sleeve for every area, eventually.



Thanks Bryce! :) I use Rhino for surface modeling (what you're looking at here), and Pro/E for solid modeling. I really love surfacing, and normally just use solid for engineering tolerance precision to back up the "look" (critical mounting points and surfaces). This one was kind of a quickie, to get the front plug wrapped up, I have some neat stuff in the works for this project though. The windshield frame is getting more involved by the minute (still surface modeling in Rhino). I keep reminding myself that it has to actually be produced. :rolleyes: Thank goodness for 3D printing. :cool:

Looks great Todd!

Thanks Greg! :thumbsup: I think I need to buy you a beer or a steak or something, for reminding me how much fun I can have! :yes: :D Hope you're getting the bugs ironed out of Redeuce.

I have a while before I get to drive the Inhaler, but I fake it a lot. I've been working on systems and stuff and sat in it for a while the other day, thinking through everything. I used Flintstone power to move around a little, cranked the wheel hard through imaginary autocross cones, and blew spit bubbles making cool forced-air cooling sounds (think centrifugal supercharger)! :rofl:

No worries, we've swamped at werk with no sign of things slowing down.
Just finished up a few big projects, starting a new one that will be huge for us, have 2 coming that will be on t.v. one a feature project, not to mention our normal werk load ..... I don't sleep much these days lol

As far as the truck goes. Yeah the front is swoopy & sleek, then the back is factory... which is now boreing compared to the front. Just some respectful input :D .

Josh

Congrats on the success in your biz! Who needs sleep? :faint:

Point taken on the back. I don't know what I'll actually do about it, if anything, but I do get what you're saying. Probably lose a lot of sleep thinking about it. Hey! Just because you can't sleep, doesn't mean you have to keep me up! :lol: Seriously though, thanks for the feedback. :thumbsup:

This project is insane. Wish I had cad and a cnc machine.

Thanks John! :thumbsup: CAD/CNC is a lot of fun. I've worked with conventional tools most of my life, eventually found CAD, and fell in love. From my perspective, it's really just another tool in my box. When I'm working in it, I am working from the perspective of grabbing some raw materials, a bunch of tools, and the desire to see what I can create.

Seeing the machines cut this kind of stuff is fun because they actually tend to mimic a good craftsman with a bunch of hand tools. When the rear motor mount was in finishing, it was like watching someone chiseling one of those huge stone monuments. At .020 stepover rate you can barely see where any material has been removed, but if you keep staring you see the shape developing right before your eyes, out of a big chunk of metal. Then, for me, I am seeing the machine mimic what I was doing on screen to create the model. Fascinating stuff! :yes:

More CAD in the works. I started out doing a more traditionally styled '30 Ford inspired windshield, but it didn't look right when I mocked it up on the vehicle. I decided to trade practicality for creativity and came up with this assymetrical, double hump, design. I still have to blend the stanchions and main rail together, but it's coming along. The stanchions are going to be 3D prints, then cast in aluminum. I want to whittle (CNC) the main rail from billet.
http://toddperkinsdesign.com/images/...ms/art/078.jpg

We've set a tentative goal to try to have it ready to do some racing next year. I really wanted to have it at Goodguys next month (in my own or someone else's vendor space), but the stars don't seem to be lining up for that, so far.

A couple blurry cell phone pics of the Inhaler's current state. I can't remember whether I mentioned it here, so I'll touch on it briefly. We're in the process of shooting a documentary about this project, which has delayed work as we tried to get a basic understanding of where we're going with the video, and then coordinate things to allow for capturing the process. The guy that's heading the documentary has shot for media giants like The History Channel, and has shot for at least one episode of My Classic Car. I saw about fifteen seconds of the promotional short when he first started editing, and it was pretty sweet.

In these pics, we have cut the new track nose (CAD pics back a page or three) and grafted it into the front clip. Hoping to do the lay-up on this clip soon. We have lots of sanding and shaping left to do to get to that though.
http://toddperkinsdesign.com/images/...ldpics/173.jpg
http://toddperkinsdesign.com/images/...ldpics/174.jpg
http://toddperkinsdesign.com/images/...ldpics/175.jpg

We got a little feature in an online alternative fuels publication. :)

Also getting started on the most ridiculous steering wheel ever. Here I laid out the first cuts on the Curly Maple burl wood block that will become the rim. When I finally get the CAD models finished, we will also start whittling about 75lbs of 6061 billet down to a 5lb center section. :unibrow:
http://toddperkinsdesign.com/images/...ldpics/179.jpg

http://toddperkinsdesign.com/images/...ms/art/088.jpg
Blazing new trails is exhaustive, but highly rewardling. I've been lost in design issues for months now, and the need was exacerbated by the availability of the motor controller, and some new motors, that my plans were hinged on. It was a risky bet that these parts would eventually be produced, but it's a dream that coming true. The 1+MW (1600hp capable) controller is in prototyping right now, and a new motor that can (hopefully) stand up to it is also in development. I had to up my game to match. I already had plans for everything that's pictured here, I just had to revise some of it a bit.

The wheelbase is going out to 108" soon, and it will have two motors just about dead-center in the chassis, with power going in both directions (AWD). I'm probably going to use C5/6 susepnsion up front, with triangulated four-link rear. Realistically, it will be capable of over 1000hp, though the weight will increase quite a bit from 1200lbs, to something closer to 2000lbs. It will still have the 2:1 weight-to-power ratio, actually better. The thing I like most is that, at rest, there will be no clue that this type of power is under the skin! :D In fact, it won't even look like there's enough there to make it a functioning vehicle! That was one of my prime goals, from the beginning. :cool:

this has to be the sweetest build on here, GO GREEN POWER!!!! lol

Thanks senor. :thumbsup: Considering the level of builds that happen on this site :hail: , that's mighty big shoes for my ratty little rod but we're trying to do something special with it. Green might also be a bit of a misnomer, considering I plan to waste enough power to light up a neighborhood, having fun! :lol:

seriously its different, thats whats so cool. I had to show all my buddies at work, everyone was like wtf, its never been done before which makes it awesome. consider me subscribed!!!!

Well thanks, I really appreciate the support. :thumbsup: :) Things tend to move kind of slow most of the time because there is so much to figure out, but once we're over the main design hurdles the pace should pick up.

Glad to see you're still working away on this. Looking forward to seeing it come together. Very cool build. What is the track width your running with the 108" wheelbase?

Thanks wellis. :) There's no turning back now, I have to get something in return for the time I have invested in it. :unibrow:

In front, right now, hub-to-hub I have about 61", and about 66-67" sidewall to sidewall (outsides).

In back, right now, hub-to-hub it's at about 59", and about 76-ish inches sidewall-to-sidewall. That will increase to 78-80" with 345 section-width tires and new rims.

Everything has to go in software to find the best compromise before the real pick-up points are welded in. It's all just mock-up now to get the component locations and body sorted out. It's really challenging to hide all this stuff under Model T skin.

Wow, I can't beleve it has been this long since I posted, and since we actually worked on this one! We did a mock-up stretch last night just to get the rear wheels in he right place. There's going to be a complete redo of the rear suspension geometry (still trangulated four-link, I think), but we can now start mounting the motor and making it actually run. First, we'll stretch the bed to fill the gap. This gives it more conventional pickup truck proportions, and us the (108") wheelbase to really push the (performance) envelope.

In a week or so, all the bodywork will be recreated in carbon fiber. More to come...
http://toddperkinsdesign.com/images/...ldpics/194.jpg
http://toddperkinsdesign.com/images/...ldpics/195.jpg

Longer and meaner...
http://toddperkinsdesign.com/images/...ldpics/201.jpg
http://toddperkinsdesign.com/images/...ldpics/202.jpg

With a new carbon fiber body shell (rough draft created right over the old fiberglass body, as we'll be cutting, splicing, and modifying it).
http://toddperkinsdesign.com/images/...ldpics/207.jpg
http://toddperkinsdesign.com/images/...ldpics/208.jpg

We've started surfaicng work on the front clip's foam plug, to get it in carbon fiber soon.
http://toddperkinsdesign.com/images/...ldpics/210.jpg

Two little 23 Ford-based hot rods beginning to take shape...
http://toddperkinsdesign.com/images/...ldpics/211.jpg

It's coming along.
http://toddperkinsdesign.com/images/...ldpics/212.jpg
http://toddperkinsdesign.com/images/...ldpics/213.jpg
http://toddperkinsdesign.com/images/...ldpics/215.jpg
http://toddperkinsdesign.com/images/...ldpics/214.jpg

So, I am closing my studio/moving my stuff out of the community workshop this weekend. Everything is going in storage for a bit, while I try to figure out "what next". I have been trying to decide what I really want to keep, to reduce the size of the storage unit, and avoid having one full of a bunch of crap I don't want. I decided that Schism was more than I want to do and got rid of it. That left me with two electric motorcycle projects and my tools, nice and tidy.

Long-story-short, the Inhaler became the property of the community workshop in our deal to (unsuccessfully) try to found a non-profit with it as the centerpiece. Monday, Alex tells me that he's handing it back to me - it's mine again...

I had to make some really fast decisions about what to do with it. I decided to keep it and return to something closer to the original plan - small, basic, raw, fun. All the crazy bodywork, and the stretched wheelbase, were to suit our non-profit goals. I pulled the crazy front clip, and the bed, shortened the wheelbase back to 90", and am going to mount the massive 13" motor up front, uncovered, with a conventional driveshaft to the rear axle. It rolls and steers already, so when I get the motor mounted and a driveshaft strung, I will be working on making it run. It will need springs and shocks, but that's a minor issue, needing only light fabrication to implement.

I call the theme I am shooting for "TechnoRat". Sort of Modified style, with just the body tub and a grille shell for bodywork, purposely not perfect - a little rat rod-ish to keep things simple, and blatantly using and displaying modern technology and components on an old hot rod. The key is that motor. It is an absolute torque monster, with every drop of it being available from 0 rpm - now! :unibrow:
http://toddperkinsdesign.com/images/...ldpics/272.jpg
http://toddperkinsdesign.com/images/...ldpics/273.jpg

Good luck, Todd.

just found this project. this is awesome stuff Todd. I've been wanting to do an EV for so long.

Thanks guys! :thumbsup: EVs are a blast. It took me a while to adjust, now I'm hooked...

Somehow, I got unsubscribed from my own thread. I didn't even know anyone had replied to it. I came today to post some updates, and saw kudos! :cheers:

This isn't the real mid plate - just a temporary way to get the motor bolted in the car so I can roll it in my storage unit. When I get settled, I will cut a real mid plate from 0.750 or 1.000" 6061 plate. That thick because of the torque characteristics of the motor. Sorry about the rust. I need to get everything blasted, then buy some Rad Rides stuff.
http://toddperkinsdesign.com/images/...ldpics/274.jpg
http://toddperkinsdesign.com/images/...ldpics/275.jpg


I pushed the body back quite a bit to get the motor out in full view, and gained the fringe benefit of a better profile; with more classic hot rod proportions.
http://toddperkinsdesign.com/images/...ldpics/276.jpg
http://toddperkinsdesign.com/images/...ldpics/277.jpg


I was pretty exhausted by the time I got the motor in and staggered back to my office and computer. I used a bunch of leftover CAD stuff I had modeled for other projects to create a 1913 style grille for it.
http://toddperkinsdesign.com/images/...ldpics/278.jpg


Then, cut it in MDF today. This is the plug for mold-less carbon fiber construction. When the carbon has fully cured, I'll removed the MDF plug.
http://toddperkinsdesign.com/images/...ldpics/279.jpg
http://toddperkinsdesign.com/images/...ldpics/280.jpg
http://toddperkinsdesign.com/images/...ldpics/281.jpg

I wasn't thinking when I modeled it and left the edges of my Bat-T logo razor sharp in the model. That machine isn't accurate enough to not destroy that edge. I can rebuild it easily though, so no real harm done...


More to come... I have Goodguys Columbus in my head. I probably wouldn't have much battery, but I would be thrilled just to drive it into the show.

I like it rough. Gives it the logo that patina rustic look.

Whats that motor weigh again?

Thanks. I see what you're saying. Maybe I'll explore keeping/capturing that as a feature. I kind of like the challenge. :evil:

It goes with the patina'd carbon look I have in mind for the rest of the car. Kind of like an old carbon fiber race car that's been sitting in a field breaking down in the elements - I guess over hundreds of years! :lol: Rather than the, oceans-deep, layers of gelcoat normally found over exposed carbon, you'll be able to feel the texture of the cloth, and there will be places where it's apparently broken, or deteriorated (thousands of years?), etc.




350lbs. This one is a GE: 13.5" diameter, 23" long case. The most popular commercially available, 13", DC, EV motor is the Warp 13, at 13.25 x 20.4"; so this is a beast of an electric motor. My motor came from a 10,000lb capacity (lift and carry) forklift.

Can't wait to feel it pull a 1200lb go-kart. :slingshot:

But this will be... :yes:
http://toddperkinsdesign.com/images/...ldpics/289.jpg
http://toddperkinsdesign.com/images/...ldpics/290.jpg

I do like where this is going

Thanks mrgm!

The steel frame mounts: 1" thick plate steel with a little CNC work, and sheet metal steel hemisphere caps TIG'd on. The plates end up being 0.500" minimum thickness, with 1" thick, drilled and tapped, bosses for the four 0.750" mounting bolts. The sheet metal caps, of course, finish the aesthetic; eliminate the need to do a blind, tapped, hole; and save a few precious ounces of weight. After some hand finishing work they should look like cast steel brackets.
http://toddperkinsdesign.com/images/...ldpics/291.jpg


My goal was to emphasize the mechanical connection of the big 13 to the chassis. Those steel domes should help pull people's attention down to the area, then the various gaps and radii will offer lots of light-play to bring out the details.
http://toddperkinsdesign.com/images/...ldpics/292.jpg

Here's the driveshaft tunnel I mentioned. The point is to emphasize function; to show what's happening inside it, and to highlight the fact that the motor is directly driving the rear end - no gears needed. I will probably revisit the section where it switches from tube to tunnel, and give it a rolled, gradual, transition. The front, tube and boot, sections will both be two-piece parts, with hidden lower panels, to allow slipping them over the u-joint and shaft.
http://toddperkinsdesign.com/images/...ldpics/293.jpg

what rear will you be running, and what ratio?