Electric MGF Bespoke Project - Dev255

[Dev255]

Hi everyone,

I love to tinker with electronics, CAD, machining, programming, car mechanics (including a recent 3.2L engine rebuild, sadly not in an MGF yet though sorry).

Now I am working on a multi-motor power unit that will fit in my MGF. It's a little different as it uses 24 radio controlled water cooled boat motors at 3kW each, so should produce just shy of 100hp and weigh in around 70kg.

I have a website at http://www.dev255.uk, a YouTube channel and a Patreon page that will show alot of the build, although want to keep it here too (I don't wish to pull anyone away). So I am happy to answer questions and take advice from the guru's of the MGF on here. Plus taking the MGF engine out (pistons had a disagreement with the valves I think) there may be some salvageable parts for you guys.

The MGF worked well for 2 months after I bought it and sailed through an MOT. Once the engine popped, it became my next project.

I intend for this one to be purely powered (charged) by the sun and not be charged at all with mains. This doesn't mean I hug trees just yet as I still have and enjoy my 3.2, just that I want to see how practical it is to drive without any fossil fuel input and I believe the MGF is the best car to try it with.

I hope you will enjoy this project.

[talkingcars]

Looking foward to this build.

One question - how do you plan to produce the vacuum required for the brake servo?

James

[Dev255]

Hi James,

I plan to have a 12V racing vacuum pump running off a large 12v AGM auxilliary battery similar to this one

https://www.summitracing.com/int/search ... cuum-pumps.

It will also need battery cut off's that can be manually pulled in case of an emergency, this is another requirement I believe.

Regards,

Neil.

[Rob Bell]

There was a London Taxi electric motor on the bay of fleas recently - the day where the parts to do electric conversions fall within the reach of enthusiasts is probably not too many years away!

Good luck with your project Dev - will be following with interest. There have been a few electric-converted MGFs built over the years - I'm sure you've found them too?

[Dev255]

Hi Rob,

I'm sure it will get cheaper, I think batteries will start getting cheaper too now and more energy dense, so exciting times.

I will ensure this post gets plenty of info and pictures too, where I am testing one of the motors tonight.

Feel free to quiz me and challenge my thinking too, sometimes I can't see the leaves through the trees.

Regards,

Neil.

[Dev255]

Hi, I'm back off my holidays, so getting back into the MGF EV project,

Here is a video making one of the parts. Things will speed up now I have everything in motion.

or https://youtu.be/uI2-QO4-ivg (can't seem to get the embed bit to work).

Have fun,

Regards,

Neil.

[Gavin207]

I'd be interested to know what battery/s you intend using - I've looked into this for a project I have ( Morris Minor) and my understanding is that batteries for electric vehicles are subject to strict approvals, and as they are generally bespoke for specific vehicles unless you can accommodate one from an existing vehicle which is already certified, then getting approval will be a challenge.

[Dev255]

Hi Gavin,

That is a good point, initially for testing (off of public roads), I'll be using LiPo standard off the shelf batteries (fairly cheap for testing).

Then if all looks good, switching to Used Tesla or similar Li-Ion batteries (these can be sort with up to 80% capacity left in).



Here are some other components that I will be using: -




Hopefully, I will get this power unit approved once built, where I will share every step in getting the vehicle type-approved before putting it on the road. I'm sure I will be in for an uphill battle, lol.

Hope that helps,

Kind Regards,

Neil.

[Rob Bell]

Watching with interest!

It was interesting to read in the current edition of FasTForward of a company using a TF to build and test a battery/ EV driveline. I'd be potentially be interested in this conversion in the long-term, but their battery installation would be quite destructive I suspect... But we do have an engine bay and front bonnet space that could be utilised for battery storage quite easily.

[Dev255]

Hi Rob, yeah we do have plenty of space front and rear, so I'll try and distribute the weight between the 2. My power unit should only produce 100 ish hp, but the torque may rip things apart a little . I'll probably be able to tow another MGF with no dramas .

I will initially be using Lipo batteries, although I'm now thinking of the safer Li-ion batt's instead as they are less volatile and are currently used in EV's.

Yesterday I started pulling the engine apart to see what had failed, so got the head off whilst it is still in the car. I'll show some pictures here later today of the failure. It looks as if I might not need to drop the sub-frame to get the engine out, may be able to dismantle it in situ.

Anyone need any parts?

Have fun,

Kind regards,

Neil.

[Dev255]

Hi, a little update as I have been dismantling the MGF K-Series yesterday, not only to find out what happened, but also to look at the mounting options for the power unit. It will be fitted directly on the existing gearbox.

My MGF sub-frame is looking very tired so may have some work to do bringing it back up to life (I purple powder coated my Vectra C sub-frame while re-building the 3.2L engine, so may do the same here ).

The engine was running well before its failure, so most of the ancill parts are in good working order, so may have to sell some of those bits.

I'll also do a video soon on my YouTube channel walking around the car with an explanation too.

Before dismantling.


Checking the Spark plugs, it turns out the first one (nearest the cam belt) had its gap adjusted in the combustion chamber , not normal operation.


The Cams and head look ok, although there's a little water in the oil channel


The easy way of removing the cams (as they wont be used again) while dismantling the engine in situ. You just need a 33mm spanner .


Not looking too bad at this point, so lets take the head off...


Ah...... I see some issues


Hmmm, now I know what happened to the spark plug. Can anyone see the crack near the exhaust valve seat?


Im thinking of a nice ornament for a coffee table ...


So I drained some of the water and all of the oil by undoing the sump plug , then draining off the rest of the water by undoing the lower pipe. The underside is looking a little tired, so may have to carry out a little re-conditioning.


The car is getting lighter and lighter, I may have to keep a running weight total of all the parts coming off.

Also, I now have some spare parts that will be sold on, anyone need anything here?

Happy MGF'ing,

Neil.

[ErikB]

Interesting on all levels: technical and administration

[Rob Bell]

Neil, I reckon I can salvage the cylinder head (it'll be a lot of work of course, but will need the head, cam ladder, all bolts and the cams etc). And I may be interested in the engine loom and ancillaries for when I convert my MGF to MEMS3. PM?

Can't see the crack you mention though? Had the cam belt snapped? Or had it snapped in the past? Really unusual to loose the exhaust valves like that. But the combustion chambers are minging. I have removed a few cylinder heads now, and have not seen one as nasty as this one...

[Dev255]

Hi Rob, Sorry for the late reply, even though I changed the settings the email notifying of a reply went to my junk folder, unlike the engine

I will PM you as requested.

[Dev255]

Interesting on all levels: technical and administration

A little time consuming too, I will upload some more pictures soon of the engine out.

Also, I have just spent £400 on motors and ESC's for the project so hopefully this will all be worth it in the end

[Rob Bell]

No worries - will catch up with you shortly

[Dev255]

Hi all,

I thought I'd give a little update.

It's taking quite some time to machine out all of the parts for the MGF Power Unit, so I am currently converting my milling machine to CNC so that I can speed up the MGF project (I am eager to get this on the road).

That said, like the MGF, I would like to power the milling machine purely from the Sun (not the newspaper! although page 3 and the MGF have something in common... ).

I am still tweaking the CAD and researching improvements for the MGF Power Unit, where I have had to change the ESC's as they no longer make the one I designed it with (the new one is better )

Here is the latest video on the MGF: https://youtu.be/hcxowURNOoQ
Here is the latest video of the CNC build: https://youtu.be/NkTtaE6oPf4

Feel free to comment, like or subscribe if you wish, I am happy for all suggestions as I know you guys are the Guru's.

[Rob Bell]

(not the newspaper! although page 3 and the MGF have something in common... ).

However, hasn't page 3 become all PC these days? May be not topless, but top-down?