Build Update 4.12.13

Last week we returned the P2 motor/generator to team sponsor Kollmorgen to fix fitment issues. Kollmorgen was very quick with the alterations and we received it back the next day.

With the P2 back in the lab, we were able to reassemble the front powertrain. Here’s to hoping the front engine, P2 and transmission assembly never have to come out of the car again! We started with the assembly of the P2 to the transmission by routing the three-phase and signaling wires from the P2 through the transmission and its bell housing. With these two connected, we sealed the P2 coolant fittings and the holes where the wires protruded.

We also removed the stock torque converter to make room for the P2, which meant the engine had to somehow be connected to the transmission with very little room. We decided to lock the engine, P2 and transmission together using the spline shafts in the P2. Since the torque developed in an engine is the result of a series of rapid explosions, the torque it delivers is slightly cyclic and varies depending on road demands. A torque damper in a manual transmission takes this uneven torque of the engine and smooths it out for the transmission, or in our case, the P2. It also helps with the gear lash involved in changing gears. This meant we needed an adapter that connects this torque damper to the original mounting points of the torque converter on the flex plate of the engine.

After developing a design and making sure it would not fail from the fatigue of cyclic forces, we created our adapter using angle and bench grinders. After the engine, P2 and transmission were assembled, we attached these to the front subframe. We then raised the assembly into the car for installation. The next step is for the electrical and controls subteams to connect all of the front wiring. Once everything is connected, we can install the P2 inverter and 12-volt battery.

We have been working hard but still have a lot of work to do before competition. Send us words of encouragement and advice in the comments below!