A new journey with my 2005 Prius

Discussion in 'General' started by Ophbalance, Jan 18, 2017.

  1. BillLin

    BillLin MASS: 2018 Bolt EV and 2017 Prime

    I have the vent guards up front for both PIP and C-MAX. The ventilation capabilities for me far outweigh any aero negatives. I hadn't thought of dust, and it hasn't been an issue. Pollen though... Vent guards all the way around for the Crosstrek. Can't do much harm to that brick shape. :)
     
  2. RedylC94

    RedylC94 Well-Known Member

    "Vent guards"= ? Are you guys referring to the old-fashioned angled awning-like things that cover the top of the window opening on the outside? If so, aren't those horrible for aero drag? If not, illustration, please.
     
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  3. BillLin

    BillLin MASS: 2018 Bolt EV and 2017 Prime

    Screenshot_2017-02-10-22-37-42~2.png
    Not the best for aero, but not too horrible. 50-55 hwy mpg is good enough for me.
     
  4. EdwinTheMagnificent

    EdwinTheMagnificent Legend In His Mind

    I can sort of see a reason for those rain guards. If I'm in the car for an hour , on a foggy,drizzly,or rainy day , I will have windshield fogging issues that might force me to use climate control with A/C. I HATE doing that, lol. So I will crack all four windows , or at least one front and one back to help keep the inside windows clear. In good weather , I can see that they will add aero drag. And I expect ( and get ) 60MPG highway in good weather.
     
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  5. S Keith

    S Keith Well-Known Member

    As an aerospace engineer, I can confidently say that the aerodynamic drag associated with rain guards is negligible. They reside almost completely within the detached turbulent boundary layer, are smooth and contoured, and represent an extremely tiny fraction of the frontal area of the vehicle. The mirrors have 30X the drag of rain guards and the relative aerodynamics of a brick.
     
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  6. Ophbalance

    Ophbalance Administrator Staff Member

    I'll pull the fan apart, soon as I find instructions on that. A cursory glance of what I can see doesn't show much dust sitting in there. The thing that likely killed mine is heat. We tend to have two seasons in my area, summer and not summer. It's going to be 80F today... in February! Summer tends to average in the 70's for the overnight highs, and usually at least some high humidity. I tend to park at work under whatever shade is available, and when home, try to leave the car in the garage. Doesn't help for the heat but it does block the sun. I think the longest time the car ever sits is maybe 2 days? Average anywhere between 400 and 500 miles a week. And unless the highway is block it's very little stop and go. Oh well, crap happens. I've finally kicked this damn flu enough to go pull the battery today. Woo.
     
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  7. S Keith

    S Keith Well-Known Member

    The fan is very straightforward 3 10mm nuts holding it on, the electrical connector on the back and another connector clipped to the upper bracket. Remove, blow out with compressed air, reinstall, done.

    Heh... heat? You have us beat handily on humdity+heat, but I think we have you beat on total BTU here in the Phoenix area.

    Parking in shade/garage helps immensely. When in direct sunlight, the interior is a green house. It's not at all uncommon for interior temperatures to hit 140°F+. With windows closed, 10-20° higher.

    Regardless of the cause, it's usually cell imbalance that eventually leads to failure when the cell at the lowest state of charge gets driven in reverse polarity at high current repeatedly. Heat also compounds the "memory" associated capacity loss. Maintenance grid charging can help minimize imbalance and controlled low current discharging can help recover lost capacity from "memory". These can help keep a battery healthy and minimize the likelihood of failure. Preventative maintenance grid charges 2-4 times per year with a discharge once per year is typically enough.
     
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  8. Ophbalance

    Ophbalance Administrator Staff Member

    upload_2017-2-12_21-3-19.png

    This is the voltage currently in the pack. I sorted had an oops on #1 and I broke off the positive post, so there's another cell I need to replace. Sigh.
     
  9. S Keith

    S Keith Well-Known Member

    Clearly #9 has a failed cell. Don't even bother cycling it. It will get ugly during charge and swell like crazy.

    How did you break off a terminal post?
     
  10. RedylC94

    RedylC94 Well-Known Member

    Would simply charging those low cells (if they can be identified) help significantly? If not, what's the theory as to why not?
     
  11. S Keith

    S Keith Well-Known Member

    Yes, but easily identifying the low cells is essentially impossible.

    NiMH is very over-charge tolerant. That's why grid charging works - you deliberately charge ALL cells to 100% state of charge (SoC) at low current. In this case you don't have to identify them.
     
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  12. Ophbalance

    Ophbalance Administrator Staff Member

    New toqrue wrench isn't as clicky as I would have expected and I sheered it off when I over tightened the charge cable/nut in place.
     
  13. S Keith

    S Keith Well-Known Member

    Ah... yeah... 48 in-lb isn't much, and the HF torque wrenches are more subtle than some.

    For the purposes of testing, since I'm not pushing/pulling 50A, I don't worry about torquing the nuts (except on the load test). I have a cordless drill that has those "torque" settings. Without fail, nuts take at least 1/8 to 1/4 turn past where my drill cuts off when set on 1.
     
  14. Ophbalance

    Ophbalance Administrator Staff Member

    So, not much to report, other than keeping on keeping on. I did pick up yet another bike that's become its own project to bring back. I managed to find a 2005 Honda VTX 1300c with ONLY 746 miles on it. I've had to replace some parts that are rubber and force vacuum into the engine that have failed, but it's going to replace my Magna as the daily commuter. From all accounts now that it's mostly running correctly it should provide a fair amount of trouble free miles.

    [​IMG]
     
  15. EdwinTheMagnificent

    EdwinTheMagnificent Legend In His Mind

    Nice. I haven't had a motorcycle for about 15 years , but I'm seriously thinking about one now. I do like the BMW singles and 800 twins , and the KTM singles.
     
  16. Ophbalance

    Ophbalance Administrator Staff Member

    This bike is just the next step on my way to the next bike. I'd like to get an FJR1300 in a few years.
     
  17. EdwinTheMagnificent

    EdwinTheMagnificent Legend In His Mind

    Honda makes an excellent UNDERsquare (73mm bore,80 mm stroke) 670 cc parallel twin. It's supposed to be very efficient and they put it in a lot of different models.
    I'm looking at their adventure bike with that engine.
     
  18. Ophbalance

    Ophbalance Administrator Staff Member

    Hey folks! It's been a bit of time, sorry. The very short version of everything is:
    • There is simply no compelling story to be had moving leads around the battery pack. It's about as much fun to watch and talk about as drying paint.
    • Most of the cells recovered nicely after charging/discharging multiple times. A few were deep cycled to make sure they would make a come back
    • 3 out of 28 were too questionable to leave in place. 1 out of 28 I broke the post on. 4 total cells were replaced
    • I'm 500 miles into the newly rebuilt pack. If this is what it was like to drive new, I've been missing out for a loooooooooooooong time!
    It's bloody awesome how well the pack is presently doing. The goal for the next month or two is to install a grid charger and manage the pack every six months or so to ensure that the fixes done will last a fairly long time.

    None of this would have been possible without S Keith's help, however. He took far too much time out of his day helping me out when needed and I'll be forever grateful for that!
     
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  19. RedylC94

    RedylC94 Well-Known Member

    Thanks for the update!

    I hope someone publishes the kind of practical how-to expertise you acquired before I (among many others) need it.
     
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  20. Ophbalance

    Ophbalance Administrator Staff Member

    Update as it's been almost a year. I'm 20,000 miles past the original issue on this rebuilt pack, and so far so good! The ODO sits right around 192k as of today. I've not seen any oddball re-calibration attempts or had any other symptoms. I still need to build a grid charger before summer hits for next year but this has been as successful as one would hope. My only complaints are my front bumper continues to fall apart after hitting that tire retread and they no longer offer the Energy Saver A/S for the stock Prius rims. Otherwise, nothing new to report!
     
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