Cheap Electric Car Drives Again With Charger Repair

If someone sent you an advert for an electric car with a price too low to pass up, what would you do? [Leadacid44] was in that lucky situation, and since it was crazy cheap, bought the car.

Of course, there’s always a problem of some kind with any cheap car, and this one was no exception. In this case, making it ‘go’ for any reasonable distance was the problem. Eventually a faulty battery charging system was diagnosed and fixed, but not before chasing down a few other possibilities. While the eventual solution was a relatively simple one the write-up of the car and the process of finding it makes for an interesting read.

The car in question is a ZENN, a Canadian-made and electric-powered licensed version of the French Microcar MC2 low-speed city car with a 72 volt lead-acid battery pack that gives a range of about 40 miles and a limited top speed of 25 miles per hour. Not a vehicle that is an uncommon sight in European cities, but very rare indeed in North America. Through the write-up we are introduced to this unusual vehicle, the choice of battery packs, and to the charger that turned out to be defective. We’re then shown the common fault with these units, a familiar dry joint issue from poor quality lead-free solder, and taken through the repair.

We are so used to lithium-ion batteries in electric cars that it’s easy to forget there is still a small niche for lead-acid in transportation. Short-range vehicles like this one or many of the current crop of electric UTVs can do without the capacity and weight savings, and reap the benefit of the older technology being significantly cheaper. It would however be fascinating to see what the ZENN could achieve with a lithium-ion pack and the removal of that speed limiter.

If your curiosity is whetted by European electric microcars, take a look at our previous feature n the futuristic Hotzenblitz, from Germany.

Massive 20-oz. Copper PCB Enables Electric Racing

Is twenty times the copper twenty times as much fun to work with? Ask [limpkin] and follow along as he fabricates a DC/DC block for a Formula E race car on 20-oz copper PCBs.

The typical boards you order from OSH Park and the like usually come with 1-ounce copper – that’s one ounce of copper cladding per square foot of board. For those averse to Imperial units, that’s a copper layer 34 micrometers thick. [limpkin]’s Formula E control board needs to carry a lot of current, so he specified 700-micrometer thick cladding, or 20-oz per square foot. The board pictured cost $2250, so you’d figure soldering on the components would be an exotic process, but aside from preheating the board, [limpkin] took it in stride. Check out the image gallery of the session and you’ll see nothing but a couple of regular high-wattage soldering irons, with dirty tips to boot.

It’s pretty neat comparing what’s needed for power electronics versus the normal small signal stuff we usually see. We’d recommend looking at [Brian Benchoff]’s “Creating a PCB in Everything” series for design tips, but we’re not sure traditional tools will work for boards like these. And just for fun, check out the Formula E highlights video below the break to see what this build is part of.

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Pioneer AVIC Infotainment Units Hacked To Load Custom ROMs

Pioneer’s flagship AVIC line of in-car multimedia systems is compatible with both Android Auto and Apple Car Play, and offers all manner of multimedia features to the driver of today. What’s more, these in-dash wonders have spawned their own community, dedicated to hacking the units. The ultimate infotainment hack is to develop custom ROMs for these devices.

What this means is that owners of Pioneer AVIC units will eventually be able to flash a custom ROM onto their in-car device, allowing it to operate more like any other generic Android tablet on the market. The potential is there for installing custom applications, extra hardware (such as OBD II readers), or pretty much anything else you can do with an Android device.

The hack involves a whole lot of delicate steps, beginning with using a USB stick with a special image to boot the device into a test mode. This allows the internal SD card to be backed up, then overwritten with a new image itself.

Mostly, the hack has been used to allow map files to be updated on the internal SD card — inability to update maps has been a long festering thorn in the side of in-dash navigation systems. Users have been customizing this to suit their requirements, also adding speed camera locations and other features. But overall this hack is a great example of hacking something to get full control over the things you own. At the least, this will allow drivers to ditch the phones suction-cupped to the windshield and run common apps like Waze, Uber, and Lyft directly on the infotainment screen (assuming you can rig up an Internet connection).

Check out another great Android ROM hack — using a cheap old smartphone as a low-cost ARM platform.

Making A Shifter Knob From Old Skateboards

Do you have a car? Does that car have a manual transmission? Do you want to beautify your shifter knob, while simultaneously gaining mad street cred, yo? Well, you’re in luck, because all of that can be done for the low, low price of a couple old skateboard decks, a lathe, and a lot of glue.

This project, from [basiltab] illustrates how you can use old skateboard decks to create really cool looking custom shifter knobs. The process starts with cutting the decks up into uniform strips, which are then glued and clamped to form small planks. Sections of the decks were alternated, to create a visually interesting pattern. The planks are then sanded so that they’re smooth and flat, and then glued up in a jig to form blocks with a threaded aluminum insert in the center. Optionally, aluminum can be used for some of the layers to add a little flair (2-part epoxy was used in place of glue for the aluminum).

After the glue has dried, the blocks can then be turned on a lathe to create the desired shape of the knob. As you can see, the results are pretty darn nifty. And, they certainly have a little more artistic credibility than the giant acrylic shifter knobs you normally find at your local auto parts store. Don’t worry, if you thought this article was about shift registers, we’ve got you covered there too.

Half A Chevy Becomes A Boat Launch

A tired 1990 Chevy Lumina isn’t the platform one would normally pick for a custom build. When you’re drag boat racing team on a budget though, you use what you can get cheap. Normally small boats are launched and landed using a trailer and tow vehicle. [Ashley Ruf’s] team at Little John’s racing is launching her boat “Kwitchabitchin” with a bit more style.

The team started by cutting the Lumina in half. Since the Chevy is a front wheel drive platform, everything behind the driver is more or less along for the ride. The gas tank was relocated, and notched to receive the front of the boat. The team then added a quad tire trailer frame. The frame is connected to the car with a long hydraulic cylinder. When the boat is being launched or landed, the cylinder can extend far enough to get the boat floating.

You might be thinking that there is no way this is street legal, and you’d be right. The Lumina only gets the boat into and out of the water. The boat is then pulled all the way forward using the hydraulics. The boat/car pair is a then perfect fit inside the team’s racing travel trailer.

You can check out a video of the car at work after the break

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Homebrew Dash Cam Enables Full Suite Of Sensors

You heard it here first: dash cams are going to be the next must-have item for your daily driver. Already reaching market saturation in some parts of the world but still fairly uncommon in North America, we predict that car makers will soon latch onto the trend and start equipping cars with dash cams as standard equipment. And you can just bet that whatever watered-down, overpriced feature set they come up with will be sure to disappoint, so you might want to think about building your own Raspberry Pi dash cam with an accelerometer and lots of LEDS.

Still very much in the prototyping phase, [CFLanger]’s project is at its heart a dash cam, but it looks like he wants to go far beyond that. Raspivid and a PI NoIR camera take care of the video streaming, but the addition of a Pi SenseHAT gives [CFLanger] a bunch of options for sensing and recording the car’s environment. Not content with the SenseHAT’s onboard accelerometer, he added an ADXL345 to the sensor suite. The 64-pixel LED display is just for fun – it displays pitch and roll of the platform – and a yet-to-be-implemented bar-graph display will show acceleration in the X-axis. He figures the whole thing is good for a couple of days of video, but we hope he adds audio capture and perhaps ECU data from an OBDII-Bluetooth adapter.

We’ve seen surprisingly few DIY dash cams on Hackaday, at least so far. There has been a dash cam teardown and retasking, and there are plenty of dashboard computer builds, though. Seems like most hackers want that DIY self-driving car first.

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Self-Driving Cars Are Not (Yet) Safe

Three things have happened in the last month that have made me think about the safety of self-driving cars a lot more. The US Department of Transportation (DOT) has issued its guidance on the safety of semi-autonomous and autonomous cars. At the same time, [Geohot]’s hacker self-driving car company bailed out of the business, citing regulatory hassles. And finally, Tesla’s Autopilot has killed its second passenger, this time in China.

At a time when [Elon Musk], [President Obama], and Google are all touting self-driving cars to be the solution to human error behind the wheel, it’s more than a little bold to be arguing the opposite case in public, but the numbers just don’t add up. Self-driving cars are probably not as safe as a good sober driver yet, but there just isn’t the required amount of data available to say this with much confidence. However, one certainly cannot say that they’re demonstrably safer.

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