Power Cube WS

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Based on collaboration between OSe and Wikispeed OSE-Wikispeed_Hybrid_Overview


File:Engine.skp

File:50hpCube.skp

File:Pc50.zip

Air_Cooled_1600cc_VW_Engine

50_HP_Power_Cube

50_hp_Power_Cube

Modular_Vehicles

6_in_60_Milestones

Hybrid_Hydraulic_System

Goals

  • 50hp
  • vibration reducing mounts

Parts

Hydraulic Pumps

gdoc calc

http://www.surpluscenter.com/hydraulic.htm

recomends halving calculation for gas engine power.

http://www.engineeringtoolbox.com/hydraulic-pumps-horsepower-d_1464.html

To find hydraulic horsepower, use the equation: HP = (PSI X GPM) / 1714

possibilities

3.87 cuin/rev, 3000rpm max, 2500 psi max

2500rpm 2000psi HP 49, gpm 42
http://www.surpluscenter.com/item.asp?item=9-7132-A&catname=hydraulic

3.18 cuin/rev, 3000rpm max, 2500 psi max

2500rpm 2000psi HP 40, gpm 34
http://www.surpluscenter.com/item.asp?item=9-7131-B&catname=hydraulic

targets

hydraulic motors

http://www.surpluscenter.com/item.asp?item=9-7022&catname=hydraulic

Vw Engine

oil pump cover gasket


Exaust

the front two cylinders have some sort of heater system that most exhausts connect to. there are some exhausts that wrap around and replace these.

models called "baja" usually have the header pointing up. "drag" seem to have header pointed backwards in the middle

http://www.gex.com/41exhst.htm

dual exhaust

heater box J-tubes replaces heater box on a standard system

http://www.dansperformanceparts.com/buggy/exh/exhaustsystem2.htm

http://www.jcwhitney.com/competition-merged-single-exhaust-systems/p2006382.jcwx

further reading

http://www.vwtrendsweb.com/tech/0109vwt_volkswagen_exhaust_test/

Tranny

http://www.qualitygermanautoparts.com/index.php?p=p1313860420

starter

http://www.mamotorworkstv.com/vw/diagram/air-cooled-vw-flywheel-and-hardware-stock/

http://www.gex.com/empi/?type=1&code=&page=9

removing nut

Sourcing Problems

pumps

  • 5000rpm pumps have small cuin/rev ratings
  • larger flow pumps max at 3600rpms
    • VW will likey be be near 4500rpms when accelerating


Diagrams

http://www.longenterprises.com/diagram_folder/diagramlist.htm

http://www.thesamba.com/vw/archives/info/

Designs

File:Vwbellhousingadapter.skp adapter plate rough design


edit

Bell_Housing_Pump_Mounting_Detail_Concept

mounting to bell housing [1]

WS+

mounted in a 4x4 XYZ frame. likely too heavy for the car, documenting here until find a better spot.

https://docs.google.com/file/d/0BwxMMqGvwTM-cnVSTlViQlVMSG8/edit?usp=sharing

issues

need to know length from front to back of bell housing.

might require adding 4 inches from front to back.

according to model of engine from web, it is slightly wider than frame. could widen by 4 inches. or could mount side by side perhaps with spacer?

no sure about exhausts yet

lengthened parts of the Undercarriage

not a cube

provisional BOM

probable exhaust conflict with frame. ideally, we need a system without heaters that has ports at or above the main belt pulley.

3373-0 $ 149.00 BUGGY DUAL EXH,W/O HTR,BLK <- side pipes that will protrude from sides of frame

http://www.parker.com/portal/site/PARKER/menuitem.bb22d5a82bbb5b147cf26710237ad1ca/?vgnextoid=a2d9b5bbec622110VgnVCM10000032a71dacRCRD&vgnextfmt=default&vgnextcatid=2618489&vgnextcat=F5OG%20MALE%20SAE%20ORB/FEMALE%20NPT%20STEEL&vgnextdiv=687620&vgnextpartno=24-1%201/2%20F5OG-S&Wtky=

http://www.parker.com/portal/site/PARKER/menuitem.bb22d5a82bbb5b147cf26710237ad1ca/?vgnextoid=a2d9b5bbec622110VgnVCM10000032a71dacRCRD&vgnextcatid=2618452&vgnextcat=CD%20STREET%20ELBOW%20STEEL&vgnextdiv=687620&vgnextpartno=1%201/2%20CD-S&Wtky=ADAPTERS&vgnextfmt=EN

http://www.amazonsupply.com/banjo-hb150ss-stainless-fitting-adapter/dp/B00AB5YY88/ref=sr_1_1_child?sr=1-1&qid=1376605325&filterBy.feature_four_browse-bin=3052061011&filterBy.size_name=1-1%2F2%22+npt+male+x+2%22+barbed%2C1-1%2F2%22+npt+male+x+1-1%2F2%22+barbed

http://www.amazon.com/dp/B003GSKXAK/ref=biss_dp_t_asn

http://estore.jwwinco.com/default.aspx?page=item%20detail&itemcode=351-60-30-M10-SS-55

http://estore.jwwinco.com/default.aspx?page=item%20detail&itemcode=451.1-38-19-5/16-55

http://www.surpluscenter.com/item.asp?item=9-7843-32&catname=hydraulic

http://www.surpluscenter.com/item.asp?item=9-8485&catname=hydraulic

http://www.surpluscenter.com/item.asp?item=9-5406-32-24&catname=

http://www.lowes.com/pd_30255-29760-60008_4294822020__?productId=4330332&Ns=p_product_qty_sales_dollar%7C1

http://www.surpluscenter.com/item.asp?item=1-3420-J&catname=powerTrans

https://www.surpluscenter.com/item.asp?item=1-3560&catname=powerTrans

http://www.surpluscenter.com/item.asp?item=1-3887&catname=wheels

Notes

tom's walkthrough

6V vs 12V [2]

gland nut and flywheel notes [3]

horsepower graph

horepower graphs

electric adapter

forum - bell housing dimensions

pipe fitting dimensions

cluctch part pictures

oil pump seal and cover

flywheel

The flywheel is a heavy, machined steel wheel that is bolted to the end of the crankshaft. The flywheel serves three purposes -

  • The primary purpose of the flywheel is to store kinetic energy and maintain the revolving inertia of the engine through its cycles.
  • Secondarily, the flywheel serves as part of the engine starting mechanism. There are teeth all around the outer circumference of the flywheel; starter gear engages these teeth to turn the engine over for starting.
  • And finally, the machined face of the flywheel acts as part of the clutch.
  • The flywheel is attached to the front of the crankshaft by four dowel pegs and very tightly secured (>254 ft-lbs) by a single central gland nut which also incorporates needle roller bearings for the gearbox input shaft.

[4]

thoughts

pump attachment

  • use clutch
    • need clutch parts
      • engagement rods and center piece
      • shafting to clutch
  • custom plate with shaft attached to flywheel
    • could use bell housing or build mount for starter and pump
      • would need coupling and shafting through bell housing
  • geardown to allow for lower rpms on pump

Links

http://en.wikipedia.org/wiki/Volkswagen_air-cooled_engine