450v

[amcp]

Someone's not playing around here. Thanks for sharing!

[dvallis]

In the process of replacing this ancient lump on the Pullmax. 1963 Swedish 440V, 3 phase, 2 speed motor.

[dvallis]

Decided to use this motor

NIDEC, 5 HP, 3 phase, 220V, 3525 RPM, NEMA, Fan Cooled, 12A FLC


Plus a a 7.5HP ABB VFD from ABB (ACS355-03U-24A4-2+J400). Has an excellent user manual


We'll re-use the original 400V FAST/SLOW/STOP buttons in the pic above (Yeah. They were directly contacting 400V!) as 12V inputs for the VFD

[dvallis]

Haven't given up, just slow going lately. Things are picking up again now the weather is finally cooling off.

I finished making a control box for the Pullmax. It communicates with the VFD I/O.

Schematic


Here's the box with test wiring. Will ultimately be mounted on a pedestal. Upper left is speed, 1000 RPM per volt. Speed control pot to the right. Below that is speed selector switch: left=slow, center=variable via pot, right=fast. Along the bottom from left are stop, start and jog buttons.

Slow part was sourcing quality switches and buttons. Amazon stuff is crap. I looked a lot on eBay for used Allen Bradley gear. Great feel and will last forever.



Up next, changing the seals and oil on the Pullmax.

[808ETA]

Woah!! This is going to be an awesome thread!

[iXguido]

Definitely going to be following this!

[dvallis]

Pullmax is alive!

https://youtu.be/ZF3icPUjGiQ

But how the #$%%% can I embed the video? Did admins change this?

[AceAndrew777]

Absolutely killer. Will be following this very closely.

[dvallis]

I owe you guys an update. We've been busy.

Wiring the VFD


Replacement knob for a Pullmax handle. Works great.


Extracting 240 lb Harbor Freight English wheel from my E39 M5 without help. Engine lift saved my back.


Some assembly required


Finished product. Needs some weight at the back. Rob wants to bolt it to the floor instead. I got the extra lower anvils from JEGS. They are EOL from Harbor Freight.

Rob scored a nice cubby shelf for organizing Pullmax tooling.



Pullmax and control box


NOW we can start making the car! Hmmmm. I've got some work ahead of me.



First test: Use the Pullmax to make a bowl.

Shear tool and guide to cut off a piece of aluminum


Circle guide to cut a round piece from that


Thumbnail die for shrinking. I'll use a polycarb die instead of steel one for the body. Leaves less dings.


Setting up Pullmax dies is an art. You jog the upper tool to lower dead center, then use the lower hand wheel to raise the lower die until contact. Then add consecutive 1/8 turns on the lower hand wheel until the "machine sound changes" while jogging. That means it's doing work. Back off 1/16 of a turn, tighten the lower collar then get to work. Periodically re-adjust while working the metal.



Doming die for stretching


(a few hours later)

And Voila! A bowl and couple of cheezy fenders. Now I'm dangerous.


We need to fab the tube frame before getting serious on body panels. Blue tape was awesome for frame planning on the buck.


The take-off showed about 250 feet required, including drop and overage.


After looking at a variety of tubing 0.50" x 0.030" DOM steel is the material of choice. Hard enough to bend, but not TOO hard. EMT was just for reference. Don't use seamed tube on a frame.


For safety sake, the crash cage will be built onto the C5 frame. Big, strong 1.5" DOM steel door bars, cockpit surround etc. The 0.5" DOM is just carrying an aluminum body.


That's about everything for now. I'm getting three quotes on 250' of 0.5" x0.030" DOM tubing and will pull the trigger on that this week.

EOM

[2mAn]

Love this kind of stuff!... I have had a few attempts at building something wild like this. None succeeded but we press on and try again

[dvallis]

Time for a pre-holiday update.

Acquired 250' of 0.5" OD 0.030 DOM for the frame



Building tube bender jigs








Building somewhere to store all our material







All that steel in the back corner goes on these shelves, plus aluminum square tube, the frame DOM, aluminum sheets, steel plate etc. Need to clean up and get organized before starting fab.

[dvallis]

Cleaned up, organized, ready to go

[dvallis]

Finally got a PC and big screen at the shop. Can reference my CAD for the build in real time. You can see the buck, body and frame overlayed.



Front frame bar interfers with the body. Needed to go.



Take out the bolts, break the glue, chop it in half and apply leverage.



Turned out great. We'll replace it with a 3"x3" square tube welded straight across.

[bangn]

wow this is a cool build! the sheet work forming is no joke! very cool

[dvallis]

New frame bar done. Might weld on a top L bracket to each side but otherwise that's all.







Body frame is next. We're starting with the cockpit surround.