The TesLorean

[DrJeff]

I got some more Tesla Parts for the TesLorean - maybe.

- Lay (intermediate) shaft (from Tesla 70D front drive unit) [drive unit is unlikely to fit with the transmission directly in the middle of the car, so this makes it easier to make the drive shafts equal length.
- Front camera (contains the Mobileye chip for autopilot - car, pedestrian, lane markings, and speed limit sign recognition)
- Rear view mirror (low profile, info)
- Light and rain sensor
- Yaw sensor
- Accelerator pedal (double redundant potentiometers) !!! Made by Ford !!!
- Air temp sensors (from climate control)
- Wiring harness

Most of these are just interesting parts that may or may not find their way into the TesLorean. I'm very interested to see if I can reverse engineer the information coming out of the Front Camera with image recognition.

[DrJeff]

Went live with the project blog website today. www.TesLorean.com
TesLorean Home.jpg
Many thanks to my brother-in-law who put all the smarts and graphics into the site! Lots of content to update still on all the happenings on the project.

[DrJeff]

Quick update on the TesLorean project...

Lots of powder coating on rear suspension parts and calipers. Getting closer to putting the wheel back on and starting the body/frame separation. Surprising what you can achieve with a toaster over, besides just toast. Got the bushings in after this photo, going in was fine, getting them out what a chore (needed two heavy duty washers with exactly the right ID). I used the Hervey "springs between the pads" again.
Power Coat on Rear Parts.jpg

Got some new Tesla parts. Picture is the PTC Heater (electric air heater). The design previously called for the same coolant loop that cooled/heated the drive unit & batteries to also heat the cabin, but after further study the heat from the drive unit / batteries would not show up fast enough to aid in defrosting the windows. The PCT heater uses battery voltage (400v) and can be instantly switched on/off and at six different heating levels. This also removes the need for a coolant loop into the airbox, so the coolant loops can stay with the batteries and drive unit.
PTC Heater Model S.jpg

Jeff

[DrJeff]

Between vacation breaks, still forging ahead with the rear suspension rebuild..

Rear Caliper and Spax Shock.jpgRear Suspension Rebuilt.jpgTrailing Arm Poly Bushing and Inconel Bolt.jpg

- Poly trailing arm bushing
- DMC Inconel bolt for the trailing arm
- SPAX shocks (adjustable)
- Powder coated, refurbished calipers
- Powder coated upper and lower control arms
- Powder coated stock rear spring
- Stainless braided flexible brake line
- Stainless caliper cross-over brake line
- Cleaned, treated, and painted frame area
(still to do : refurbish and rebuild parking brake)

[DMC-81]

Looking great!

[Lwanmtr]

Looks like an awesome project....hope you're documenting all of it...hehe.

[DrJeff]

I scrapped together this listing from multiple postings on this forum (thanks to all the contributors!). I've already got most of the 'disconnect' items done, but I wanted to get a checklist together to be sure I didn't miss anything.

I'll be doing the lift on a MaxJax 2 post lift, probably doing the separation at an upcoming Tech Day - so I can attract some extra eyes. Frame will be set down on wheel dollies (just to make moving it around the garage a little more flexible), and the body will go onto some mover dollies connected with a temporary frame (to make it movable - and not stuck on the lift). Once separated the engine and transmission are coming out, and ready for positioning the Tesla motor and measuring for mounts and axles.

Body Frame Separation

- Disconnect
- - Front
- - - Bracing
- - - - Front radiator shroud
- - - AC
- - - - Evaporator Lines @ passenger wheel well
- - - Coolant
- - - - Heater Core lines @ front firewall
- - - Control
- - - - Steering linkage @ firewall
- - - - Speedo cable at Angle Drive
- - - - Brake lines @ master cylinder
- - - Electrical
- - - - Radiator Fan lines @ front frame
- - - - Horn lines @ front frame
- - - - Fuel level sender wiring @ sender
- - - - fuel pump wiring @ fuel pump
- - - - Front lighting wiring/ground junction area @ front crumple tubes
- - - Fuel
- - - - Fuel filler hose @ fuel tank
- - - Hydraulics
- - - - Clutch line @ master clutch cylinder
- - - - Brake lines @ master cylinder
- - Cabin
- - - Shift boot and shifter @ console/shifter area
- - - Mode switch vacuum lines @ engine bay / driver's pontoon ?
- - Engine Bay
- - - Control
- - - - Throttle cable @ spool
- - - Electrical
- - - - Engine wiring @ connector box
- - - - O2 sensor @ sensor
- - - - Alternator Power @ alternator
- - - - Starter Power @ starter
- - - - Automatic Transmission computer lines (if applicable)
- - - - Battery ground cable @ passenger lower control arm AND @ rear frame
- - - - Frame/body grounds @ rear quarter stainless panels
- - - Emissions
- - - - Carbon Canister lines @ drivers pontoon
- - - Air
- - - - Air duct to filter box @ passenger's pontoon
- - Rear
- - - Control
- - - - Emergency Brakes @ each brake caliper / rear hub
- - Rear Fascia
- - - Engine cover release cable @ release
- - - Rear tail lights (for access)
- - - Fascia wiring assembly @ inside rear fascia
- - - Bolts along bottom of fascia
- - - Rear fascia assembly (whole)
- Bolts Removed
- - 2 bolts in the trunk bolting to shock towers
- - 2 bolts inside near center console bolting sideways into the frame
- - 2 bolts near the transmission/engine connection bolting the frame the body to the frame
- - 2 seat belt bolts @ inner side of seat
- - 2 in rear pontoons @ pontoon inside, after rear fascia removed
- - 2 above the rear shock towers (under shock tower brace)

[Lwanmtr]

Thats a big list. Cant wait to see how the project progresses.

[Nicholas R]

We should make that list alone a sticky'd post. People are often looking for a comprehensive list of the items that need disconnected in order to do a body/frame separation.

Keep up the good work!

[DrJeff]

Made good progress running through the checklist in preparation for the body-frame separation. As Nick suggested, I'll create a new thread with the separation checklist included, I just wanted to 'test run' it on 6313 first. I have already found some updates (such as the rear marker lights needing to be pulled back into the rear fascia), but more on that later.
Rear Fascia Removed 6311.jpg
When I got the rear fascia off of 6313, it looks like I might have the frame of 6311. If you're out there 6311, I've got your frame. I've got to think that this was something that happened at the factory. Perhaps the 6313 frame was pulled from the line for a fix and 6311 stood in to keep things flowing, or 6311 was written by mistake on the rear frame? The VIN number under the headliner on the driver's door is consistent with the VIN tags, i.e. 6313.