Freelander 1 Freelander EV

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So today I made a bracket and learned an important lesson. My overalls are NOT fire retardant, :eek:

So I started by roughly cutting out the shapes and grinding back the IRD hole to a tight fit, then fitted the other two holes.
IMG_20210221_155657002 (1).jpg
IMG_20210221_155712985.jpg


Once I was happy with the holes I bent it to fit around a ridge on the motor, then spent a bit more time grinding as the bend made it too tight but after lots of bending, bashing and grinding I was happy enough to call it a day.
IMG_20210221_175217985.jpg
IMG_20210221_155701906.jpg
IMG_20210221_175229965.jpg

IMG_20210221_175238036.jpg


In all I must have spent 6 or 7 hours on this one bracket and I still need to drill the holes and fettle and weld on the side part but it will be strong and is a nice tight fit so I'm happy it will do the job. :)
IMG_20210221_175305507.jpg


So apparently grinding produces hot sparks that can set fire to stuff. :confused: o_O
Who knew????
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I was happily grinding away thinking my overalls were fire retardant so not too concerned that I was in the way of the sparks. After a minute or two I felt a bit warm, then a bit more warm, then I looked down and saw flames. :eek:
After a bit of panic and patting down the fire was out and no major harm done but I think I might invest in a welders apron as it's not the first time I've trashed fleeces and coats. Just the first time I've set fire to myself. :p
 
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Whoops!!! Gld there were no injuries.
Sparks always feel more harmless then flames but you make a good point!!

Lesson to all.
There is so much oil on my overalls at the moment I would have gone up like Mr Fawkes!!!
 
Alibro said:
Once I was happy with the holes I bent it to fit around a ridge on the motor, then spent a bit more time grinding as the bend made it too tight but after lots of bending, bashing and grinding I was happy enough to call it a day.
View attachment 231527 View attachment 231537 View attachment 231528
View attachment 231529
Click to expand...
How the frack are you bending that 5mm steel?

Alibro said:
I was happily grinding away thinking my overalls were fire retardant
Click to expand...
They will be FLAME retardant. Basically, they will smoulder away, and never combust as a flame. The combustion of the fabric releases a shielding gas that stifles the flame from forming
 
Alibro said:
So today I made a bracket and learned an important lesson. My overalls are NOT fire retardant, :eek:

So I started by roughly cutting out the shapes and grinding back the IRD hole to a tight fit, then fitted the other two holes.
View attachment 231525View attachment 231526

Once I was happy with the holes I bent it to fit around a ridge on the motor, then spent a bit more time grinding as the bend made it too tight but after lots of bending, bashing and grinding I was happy enough to call it a day.
View attachment 231527 View attachment 231537 View attachment 231528
View attachment 231529

In all I must have spent 6 or 7 hours on this one bracket and I still need to drill the holes and fettle and weld on the side part but it will be strong and is a nice tight fit so I'm happy it will do the job. :)
View attachment 231530

So apparently grinding produces hot sparks that can set fire to stuff. :confused: o_O
Who knew????
View attachment 231531 View attachment 231532 View attachment 231533

I was happily grinding away thinking my overalls were fire retardant so not too concerned that I was in the way of the sparks. After a minute or two I felt a bit warm, then a bit more warm, then I looked down and saw flames. :eek:
After a bit of panic and patting down the fire was out and no major harm done but I think I might invest in a welders apron as it's not the first time I've trashed fleeces and coats. Just the first time I've set fire to myself. :p
Click to expand...
The end support is looking good Ali, although I suspect the 5mm steel plate is overkill here.

I'm well experienced at setting fire to overalls, which I've done a few times now. Oil soaked overalls burn really well, and are also hard to put out.
At least only the under clothing got burnt, and not your skin.
 
Alibro said:
Sorry I should have replied sooner.
Here is a couple of photo's showing the situation. As you can see there is another bolt beside it so I'm not concerned there is any problem with strength. The socket had to be cut back and ground down on one side so will never be used as a socket again anyway. I'm happy it will be OK and if I have second thoughts I'll follow your advice and use an Allen head bolt.
.View attachment 231400 View attachment 231401

On the subject of a bracket to hold the IRD and Motor here is a CAD templet of the bracket (Binky style) I'm planning to make. BTW thank you to whoever it was that first mentioned this as to be honest it hadn't occurred to me it was required. On reflection the IRD would have been very badly supported without something.
View attachment 231403 View attachment 231404 View attachment 231405

It will be made in two pieces from 4mm or 5mm steel plate and welded together so should beplenty strong enough. I probably don't need the side piece but thought it would give the bracket some stiffness.
Click to expand...

No probs. If you do get stuck for a simple turned part, give me a shout. I'm sure the socket will work fine though!

And yes, as others have said, I think 5mm might be overkill!
 
Jayridium said:
How the frack are you bending that 5mm steel?
Click to expand...
With this, I made it from some old angle iron a couple of years ago. :)

IMG_20210222_165344610.jpg


And this is the two parts upside down. The flat plate keeps it hooked on my vice really well
IMG_20210222_165418015.jpg

Jayridium said:
They will be FLAME retardant. Basically, they will smoulder away, and never combust as a flame. The combustion of the fabric releases a shielding gas that stifles the flame from forming
Click to expand...
I don't know if it was the overalls or the jumper underneath that was doing the flaming but something was and the flames were climbing towards my chin. :eek:
Because I was wearing a dust mask and helmet with perspex screen and ear defenders my senses were a bit dulled so it came as a shock when I looked down and saw flames.
Still no major harm done. :p
 
Alibro said:
With this, I made it from some old angle iron a couple of years ago. :)

View attachment 231567

And this is the two parts upside down. The flat plate keeps it hooked on my vice really well
View attachment 231568

I don't know if it was the overalls or the jumper underneath that was doing the flaming but something was and the flames were climbing towards my chin. :eek:
Because I was wearing a dust mask and helmet with perspex screen and ear defenders my senses were a bit dulled so it came as a shock when I looked down and saw flames.
Still no major harm done. :p
Click to expand...
The home made pressbreak is mint! I'm going to have a go at replicating that...
 
I'm looking forward to seeing the new setup in the engine bay Ali.
You'll then be in the position to make up the RH mount and tie bar brackets to get the RH drive shaft back in the order location.
I'm looking for to the next installments. :)
 
Nodge68 said:
I'm looking forward to seeing the new setup in the engine bay Ali.
You'll then be in the position to make up the RH mount and tie bar brackets to get the RH drive shaft back in the order location.
I'm looking for to the next installments. :)
Click to expand...
Somehow I've managed to loose my bottom bracket and tie bar so I'm going to have another look for them. If I can hot glue the two brackets together it will put everything in the perfect location with only the height to figure out.
 
So I think I may have got to the bottom of the lost bracket.

IT WAS NEVER THERE!!!! :eek: :oops:

I was busy looking for this
20160217_223717_zpsrtfjf9xp.jpg


But after looking at Rave it seems this is a 1.8K series bracket and since I took the picture several years ago that is probably true.
As it is a while since I removed the IRD I had forgotten what I had removed and I had assumed the tie bar brackets were the same for all Freelanders.
So I went back to the bracket I have and it looks like it will be simple enough to trim it down and hot glue it to my new bracket in a way that will support the motor securely.
IMG_20210223_222618980.jpg

IMG_20210223_222630544.jpg
 
Alibro said:
As it is a while since I removed the IRD I had forgotten what I had removed and I had assumed the tie bar brackets were the same for all Freelanders.
Click to expand...

The brackets do vary a bit Ali. It's years since I've studied one in detail, but the V6, TD4, 1.8K and L series are all slightly different.
The TD4 auto bracket looks like this, which might just bolt up to the tie bar bracket you have there?
Screenshot_20210224-080307_Samsung Internet.jpg

The V6 one is different again, and you know what the 1.8 bracket looks like. ;)
It's just a case of making one work for you, in this installation. :)
 
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I made a bit more progress today, thought I was finished then realised I've more to do. :eek:
So I spent the day marking out and drilling the holes, adjusted to let the tie rod bracket fit under the main bracket then fettled the side bracket a bit more and welded it on.
IMG_20210227_182134657.jpg

So as I was on a run I welded on the tie bar bracket too and trimmed it back.
IMG_20210227_182129200.jpg

IMG_20210227_182144709.jpg


So I was all pleased thinking I had finished, then remembered I still need to brace the tie rod bracket so I guess that's a job for tomorrow. :rolleyes:
 
Alibro said:
So as I was on a run I welded on the tie bar bracket too and trimmed it back.
Click to expand...
Looking good Ali.
I'm curious. How did you work out where the lower tie bar bracket needs to be?

Have you now fitted the clamps on the splines, to maintain the coupler location?
 
Nodge68 said:
Looking good Ali.
I'm curious. How did you work out where the lower tie bar bracket needs to be?
Click to expand...
I made a CAD template first, traced it out on the steel and twisted it to shape. It was far too big at first so I spent a while trimming bending and grinding but it came out well.
IMG_20210220_153945653 (1).jpg

Nodge68 said:
Have you now fitted the clamps on the splines, to maintain the coupler location?
Click to expand...
Yes mate, I used a clamp that was a fraction too small and filed it out with a half round file. The next size up was too big so I didn't have much choice. It's fitted with loctite on the screw.
 
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So I hope this is the final update on the bracket. :rolleyes:
I was a bit concerned the lower tie arm bracket was not being supported fully and might twist with constant accelerating and regen, so with this in mind I made up a gusset and hot glued it in.
First I cut a piece of angle iron to shape and welded it in, then added another piece of flat steel with a flange bent into it. Then all happy with myself I trial fitted the motor mount and realised the grinder needed to come out again. :(
It is quite possible all this lovely bracketry will need cut back when I go to fabricate the motor mount but for now it will do.
No progress shots here (you've all suffered enough) but hopefully you can see what I've done.
IMG_20210228_135523775.jpg
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Looks like a factory LR electric motor option!
Once all the mechanicals are done the electronics will hopefully be less of a grind!! Literally.
Great progress.
 
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