C5ALIVE Forum

C5Alive General Category => C5 Chatroom => Topic started by: alexbromo on 21, May, 2010 - 23:47:48

Title: Some works before put on the road ...
Post by: alexbromo on 21, May, 2010 - 23:47:48
As told in the welcome section, I'm trying to put on the road my C5.

I'm waiting for new tyres and tubes from a local bike shop, so this evening i went to the garage to see how to proceed and take some picture (sorry for poor quality, i used my mobile phone). :(

First of all: i washed the C5 using a strong degreaser (Resol) and a rough sponge, so now i discovered the underlying white !  ;D

Also the bar installed under the shell for two days has done the job, and the twist on the shield has finally been straightened.

(http://img638.imageshack.us/img638/8844/c52.jpg)

(http://img594.imageshack.us/img594/174/c53.jpg)


Here are all the items I've found in the box:

(http://img218.imageshack.us/img218/8373/c51.jpg)

the only item missing seems to be the battery cover, so i have two ignition switches hanging to the cables: i will build a sort of new cables to connect the battery (or batteries).

Finally i dismantled the power electronic and i discovered a point of fault at the connection of RED output motor cable:

(http://img341.imageshack.us/img341/3922/c54.jpg)

For unknown reason, in that point the cable overheated and burned the PCB area, destroying also the near diode:

(http://img6.imageshack.us/img6/517/c55c.jpg)

(http://img203.imageshack.us/img203/6710/c56q.jpg)

(http://img641.imageshack.us/img641/3166/c57.jpg)

so must know the type of diode to replace it ! Then i will try to strengthen the burned printed circuit soldering it.

Below two ignition switches:

(http://img294.imageshack.us/img294/3152/c59.jpg)

(http://img30.imageshack.us/img30/8346/c58g.jpg)

I believe that the blue cable is NEGATIVE and the brown is POSITIVE, right ?  :)

Alex Bromo
Title: Re: Some works before put on the road ...
Post by: PLOD11 on 22, May, 2010 - 01:18:43
Yes you are right brown Pos and blue Neg ....

That Circuit board looks in a bad way, but is repairable.

Have a look here for the circuit diagrams for the control box etc, this will help values of components.

http://www.c5alive.co.uk/downloads2.htm

John
Title: Re: Some works before put on the road ...
Post by: radiomarty on 22, May, 2010 - 07:23:12
Hi the diode is an 1N5401 ie the commutation diode - just replaced a burnt out one myself - the burning may be the result of the connection becoming loose and 'arcing'.
Title: Re: Some works before put on the road ...
Post by: coverman on 25, May, 2010 - 10:28:31
glad to see that your Porsche is Guards Red, same as mine.
Title: Re: Some works before put on the road ...
Post by: alexbromo on 08, June, 2010 - 08:14:03
coverman that Porsche is not my car, it is a frined's racing 911 that i hosted in my workshop for the night before a race.

I restored the C5's control unit replacing the commutation diode and the connection plate:

(http://img63.imageshack.us/img63/5960/84151392.jpg)

(http://img36.imageshack.us/img36/6297/58723268.jpg)

I rebuild the plate using a 2mm aluminium bar, shaped and drilled as original, but i guess that the electrical characteristics are a lot different from the original item.

I read in the "Unofficial" documentation, that this metal plate must have a specific resistance (very low), so i believe that this new alu plate can't be adequate for the circuit ...  :(

Alex Bromo
Title: Re: Some works before put on the road ...
Post by: coverman on 08, June, 2010 - 09:19:48
You have a very spacious workshop even if the Porsche is not yours! I am not brave enough to tackle repairs to the control box so your work is admired.
Title: Re: Some works before put on the road ...
Post by: aladds on 13, June, 2010 - 21:56:56
I think an aluminium plate shouldn't do any damage, but due to the current going through it there is a possibility it could melt. A piece of steel should be fine, as that's what I think the original is.
It's not a specific resistance, you're thinking of the current shunt near the bottom (different piece of metal with 4 connections to it).

I notice that there's a replacement fuse in your box from that picture, might be worth checking to see if it's the right value, a fuse which isn't clear usually means it's a household fuse, which certainly shouldn't be used in a C5! (possibly led to the burning issue it's had!)
Title: Re: Some works before put on the road ...
Post by: Retro Andy on 15, June, 2010 - 21:03:02
You have got three great classic cars in your workshop, do you specialise in VW's as I noticed the front of a camper on the wall up high I think ?

Retro Andy.
Title: Re: Some works before put on the road ...
Post by: alexbromo on 16, September, 2010 - 12:18:15
You have got three great classic cars in your workshop, do you specialise in VW's as I noticed the front of a camper on the wall up high I think ?

Retro Andy.
You have a good view, it is an ald front of a Samba Bus

(http://www.vw-samba.co.uk/images/vw-samba-2-300.jpg)

that actually we are restoring.  :)

Incidentally, last month we bought a '69 Beetle ... ehm ...

 (http://img534.imageshack.us/img534/5620/maggiolo.jpg) 
;D

Alex Bromo
Title: Re: Some works before put on the road ...
Post by: alexbromo on 16, September, 2010 - 12:40:27
After the stop due the summer holidays, works around C5 started again.

I completely disassembled the vehicle and restored the frame. It was a bit rusted and the paint disappeared in various areas, so i treated it with sandpaper and then with Fertan (specially on rusted areas)

(http://img38.imageshack.us/img38/9320/c5ap.jpg)

(http://img80.imageshack.us/img80/4464/c5bb.jpg)

and then resprayed using a very robust paint (specific for car's wheels)

(http://img255.imageshack.us/img255/6291/c5c.jpg)


the fork has just painted with primer.

I also bought new tyres and tubes (Kenda because Schwalbe aren't available in Italy)

(http://img441.imageshack.us/img441/4687/c5de.jpg)

... and a little temptation ...

(http://img529.imageshack.us/img529/690/c5g.jpg)

(http://img716.imageshack.us/img716/1927/c5et.jpg)

 ;D

Alex Bromo
Title: Re: Some works before put on the road ...
Post by: Karl on 16, September, 2010 - 13:03:28
looking good so far mate  8)
Title: Re: Some works before put on the road ...
Post by: coverman on 16, September, 2010 - 16:18:35
Hi, if that Kenda tyre is the same as I have on my front wheel., it has a maxiximum inflation pressure of 36psi. Mine would come off the rim at 40 psi, but at 35 psi survived 2 laps of the Brooklands circuit ( at a speed a racing tortoise would have been ashamed of). I run Schwalbe rear tyres at 55psi( as my gauge won't read to the 60 psi maximum permitted). This high pressure removes the likelihood of much sidewall compliance hence reducing the tendency to roll
Title: Re: Some works before put on the road ...
Post by: Karl on 16, September, 2010 - 16:26:28
Although the Schwalbe tyres cope with the higher tyre pressures, I'm not so sure the plastic wheels cope all that well.

Adam Harper always recommended sticking to the original Sinclair figures...I compromised and stuck with 40psi for the rear.

Fitting a steel front wheel permits higher pressure at the front.
Title: Re: Some works before put on the road ...
Post by: Retro Andy on 17, September, 2010 - 06:12:53
Looks like its going to be another nice C5 back on the road when you have finished, please keep the pictures coming of it and the VW's.

Retro Andy.
Title: Re: Some works before put on the road ...
Post by: alexbromo on 19, September, 2010 - 21:15:37
Hi, if that Kenda tyre is the same as I have on my front wheel., it has a maxiximum inflation pressure of 36psi. Mine would come off the rim at 40 psi, but at 35 psi survived 2 laps of the Brooklands circuit ( at a speed a racing tortoise would have been ashamed of). I run Schwalbe rear tyres at 55psi( as my gauge won't read to the 60 psi maximum permitted). This high pressure removes the likelihood of much sidewall compliance hence reducing the tendency to roll
My Kenda tyres reports 40 psi for front and 65 for rear ...

Alex Bromo
Title: Re: Some works before put on the road ...
Post by: alexbromo on 04, October, 2010 - 08:36:20
Friday has arrived the rotor for front disk brake mod !

Yesterday i've machined off a fraction of material from the wheel to slip the disk in side and take some measurement to invent a decent locking system ...

(http://img810.imageshack.us/img810/5453/c5hr.jpg)

(http://img833.imageshack.us/img833/4985/c5ih.jpg)

 :)

Alex Bromo
Title: Re: Some works before put on the road ...
Post by: radiomarty on 04, October, 2010 - 18:37:38
Looking good dude
Title: Re: Some works before put on the road ...
Post by: PLOD11 on 04, October, 2010 - 20:22:37
I second that, it does look good, i might try something like this my self.

John
Title: Re: Some works before put on the road ...
Post by: alexbromo on 08, December, 2010 - 11:35:47
I straightened the distorted rear axale (wheels turned obviously wrong): i placed it on the lathe and gently pushed it using a press:

(http://img258.imageshack.us/img258/4282/c53012.jpg)

(http://img130.imageshack.us/img130/6081/c54y.jpg)

I started to reassembly the trike:

(http://img841.imageshack.us/img841/8766/c5101.jpg)

(http://img716.imageshack.us/img716/7726/c52012.jpg)

 :)

Alex Bromo
Title: Re: Some works before put on the road ...
Post by: Karl on 08, December, 2010 - 12:08:07
Looking better than new  8)
Title: Re: Some works before put on the road ...
Post by: techytype on 09, December, 2010 - 11:12:27
great work, looking at the pre assembled picture, made me wonder if fitting another chain tensioner to the upper upper legnth of chain given how long the expanse is, when your not peddling at least the chain is held better over bumps.

does anyone feel there would it be a bennifit?

Alan
Title: Re: Some works before put on the road ...
Post by: alexbromo on 12, December, 2010 - 09:49:53
Finally the shell re assembled to the frame.

(http://img204.imageshack.us/img204/3278/imgp0050o.jpg)

(http://img253.imageshack.us/img253/4125/imgp0051q.jpg)

The windshield is still a little distorted, so i'll try to use a thermal gun.

Alex Bromo
Title: Re: Some works before put on the road ...
Post by: vanpeebles on 12, December, 2010 - 19:20:00
Big thumbs up for the calendar with the mini on!  ;D
Title: Re: Some works before put on the road ...
Post by: alexbromo on 12, December, 2010 - 21:00:39
Big thumbs up for the calendar with the mini on!  ;D

ahah ... yes it' a nice calendar distributed by "Quattroruote", a popular italian car magazine.

I love Mini, i have got a '82 Austin Mini Clubman Estate ...

(http://img710.imageshack.us/img710/1807/c5mini.jpg)

 ;D

Alex Bromo
Title: Re: Some works before put on the road ...
Post by: Karl on 12, December, 2010 - 21:57:49
A c5 and a mini - you have excellent taste  8)

Excellent job on restoring the c5 , it looks superb  :)
Title: Re: Some works before put on the road ...
Post by: Retro Andy on 13, December, 2010 - 05:53:07
The C5 looks really good, top job mate, and the mini is really nice too, look after them  :)

Retro Andy.
Title: Re: Some works before put on the road ...
Post by: alexbromo on 13, December, 2010 - 07:43:18
Many tanks !  ;D

After C5 pimping, next step is a new disk brake mod for my Mini ! Original drum brakes does not more guarantee adequate performarces for new 1330 Cooper engine ...  ::)

Alex Bromo
Title: Re: Some works before put on the road ...
Post by: vanpeebles on 13, December, 2010 - 10:39:48
That Clubman looks lovely, I bet the Italian weather is kind on the clubby too. I own a 95 Mini Mayfair(currently under restoration)  :)
Title: Re: Some works before put on the road ...
Post by: Retro Andy on 14, December, 2010 - 06:09:09
Just the Italian job  ;D

Retro Andy.
Title: Re: Some works before put on the road ...
Post by: alexbromo on 19, December, 2010 - 18:34:28
In the afternoon i rebuilt the control box and tested the electronics and motor: just connected the battery on X1/X2 the pod lights up (first+last LEDs on left gauge and all LEDs on the right).

I tried using the little bike's battery: when pressed the motor switch, the motor has started @6A with no load and the second LED (green) of the load gauge has lit. When the battery voltage reached 11.8V the buzzer is started then after few time the motor has stopped.

I do not understand what they are the X7/X5 on the control box, and how to put all the C5's electronics under the key switch to avoid to disconnect/connect the battery when the vehicle is parked.

Alex Bromo
Title: Re: Some works before put on the road ...
Post by: Karl on 19, December, 2010 - 19:29:27
I think Chas, Marty or Plod are your best bet for an answer mate. My knowledge of lectrikery is not the best  ;D
Title: Re: Some works before put on the road ...
Post by: alexbromo on 03, January, 2011 - 21:47:42
a couple of shots taken tonight with team's logo on ...

(http://img220.imageshack.us/img220/2123/rwt1.jpg)

(http://img443.imageshack.us/img443/4246/rwt2.jpg)

 ;D

Alex Bromo
Title: Re: Some works before put on the road ...
Post by: vanpeebles on 03, January, 2011 - 21:58:31
Haha ace, hey Alex do you know much about 70s Italian police films?
Title: Re: Some works before put on the road ...
Post by: alexbromo on 03, January, 2011 - 22:46:04
Haha ace, hey Alex do you know much about 70s Italian police films?

ahaha ... yes i like it a lot.

In Italy the genre is called "polizottesco" ("Milano calibro 9", "La Polizia ringrazia", "Roma violenta" ...) were a lot of Honda Four, Kawasaki Mach III, Alfa Romeo and Citroen DS running crazy (but no C5).

:D

Alex Bromo
Title: Re: Some works before put on the road ...
Post by: vanpeebles on 04, January, 2011 - 08:15:37
Hehehe I've been watching a lot of them lately. Films like Manhunt and The Big Racket. I own an Alfa myself so you get to see plenty on them. It's tricky trying to find them dubbed or subbed into english.
Title: Re: Some works before put on the road ...
Post by: alexbromo on 12, January, 2011 - 21:42:35
... uhmmmm ...

(http://img266.imageshack.us/img266/9272/tubo1u.jpg)

 ::)

Alex Bromo
Title: Re: Some works before put on the road ...
Post by: alexbromo on 12, January, 2011 - 21:45:01
WOW !

(http://img837.imageshack.us/img837/4352/tubo2.jpg)

 :o

Alex Bromo
Title: Re: Some works before put on the road ...
Post by: vanpeebles on 13, January, 2011 - 07:34:27
Haha that's a good use for those. I usually take them out of PC cases.  Also I watched Street Law last night, it was superb!
Title: Re: Some works before put on the road ...
Post by: alexbromo on 13, January, 2011 - 08:15:11
Haha that's a good use for those. I usually take them out of PC cases.  Also I watched Street Law last night, it was superb!
I seen that cone yesterday, bolted in a discarded case cover and i removed it and later i tried to install on the C5's motor: it fit perfectly !!!  ;D

Now i taken a PC 12V fan, so i'll try to put on.

"Street Law" in Italy was "Il cittadino si ribella" (approximately: "The citizen gets mad").

(http://upload.wikimedia.org/wikipedia/en/thumb/4/48/Street_law.jpg/220px-Street_law.jpg)

A great Franco Nero !   ;)

Alex Bromo
Title: Re: Some works before put on the road ...
Post by: vanpeebles on 13, January, 2011 - 08:21:36
I shall start a polizottesco in the off topic section and we can talk there  8)
Title: Re: Some works before put on the road ...
Post by: alexbromo on 13, February, 2011 - 20:45:01
Yesterday i tested the C5 around home: it is very amusing !  ;)

The new 40Ah gel battery does not take all charge anymore, so the duration of runs is still limited ... moreover the battery "monitoring" strategy of POD does not help: the gauge can only decreases and sometimes it buzzes and disconnect the motor, so must cycle (on/off) the power to have a new full gauge ...

The other problem is the load indicator: with no motor activated, firts+last led lights, but when the motor is running only the first (green) led light. No other led never light, even wen the motor is under heavy load ...  :(

... ULA damage ?

Alex Bromo.