This post really picks up from the initial development in Part 1. The reason for creating a seperate post and not adding to the first is because I chose a different design due to the materials used, and the physical limits they have. The bodywork / cladding of the Twizy is made of formed plastic. This was my anchor point for the rear wing i am fabricating. As you can imagine the material flexes as it was only ever designed to offer cladding, style and aerodynamics. As a standard Twizy, it’s smooth shape would offer next to no wind resistance at the rear, and there would be no need to have to anchor the rear bodywork to the main structure other than a few self tapping screws and locating lugs. So, introducing a whole load of additional components to the rear cowling was only ever going to increase the stresses imposed on it, and I felt that the extra weight would be a major contributor to its failure.
So I adapted my strategy based on the above, and chose a slightly less radical approach. I had done most of the hard work last year in creating the upper aerofoil element, and connecting bracket. Items were also fabricated for the full on “F1” style side foils and lower wing.
So my compromise was for the fitment of the upper wing, along with some small side elements. I made these out of some thin aluminum sheet. This was carefully cut after a template was made, drilled, folded where necessary, etch primed and painted, before epoxy gluing, and pop riveting together.
As you can probably imagine, even though the components were relatively small, this was not a particularly quick process. That said, I feel it was all worth it in the end. The following photos show the final product once painted, bonded to the bodywork and fixed to the car.
I will conclude this by saying that this may or may not be the final product. It’s more discreet than the full on F1 Twizy spoiler, but it would still be nice to have been able to have gone down that route. I feel that this is really a matter of materials and the structure they offer. With Carbon Fibre this could have been easily achieved, but I am happy to have been able to make my Twizy a little more unique with this compromise. 🙂
This weekend for Mandy and myself happens to be a long one with us both having the Friday off work. As our month long trip to Croatia looms ever closer the pressures to organise the locations / campsites increases. For months we have been consistent in our promise to organise the trip as each weekend passes, we have also been equally consistent at not doing so, due to the distractions of home life.
So our main aim of this micro stop over at a local campsite was to do as little as possible other than get us into camping mode, and plan our holiday.
We have broke the camels back in as much as we have booked our ferry crossings and two nights in Bruges to start the vacation. We also have our eyes on two very nice campsites on the shore of the aptly named Wolfgangsee Lake, and have earmarked some really nice campsites but on the coast of Croatia.
So this single nights stay has been a success. We are a little more relaxed (which is always the case after staying in idyllic surroundings in the van), and looking forward to our main 2019 holiday with enthusiasm, instead of trepidation.
The campsite we chose for this single night stop over was just about as local as it gets. Ashbourne is about 30 minutes from our home which was ideal to maximise our stay and limit fuel. I have stayed here in the past for a couple of nights on my own when recovering from a shoulder injury. It’s surrounded by pine tree and has a cosey feel to each pitch. It’s well maintained with excellent toilet & shower facilities.
I had noticed that the power reel supplying my Twizy with electricity had begun to trip on an ever increasing basis. Along with this the plug was getting pretty warm as it charged the car. I thought that this must have been normal as I had no previous benchmark to draw an alternative conclusion against. Little did I know that things were only ever going to get worse.
I attempted to charge the Twizy one evening, but came out later that night to find that the reel had tripped again. So I reset it and got up the following morning to find it had only put a small amount of juice into the battery until it tripped again. So I reset yet again, had my breakfast and popped out to the garage just before I went to work. Fortunately I did as the plug had started to melt which had also damaged the power reel.
I counted myself very lucky especially as the reel was resting on a carpet in the garage. For whatever reason the fuse didn’t blow, but on inspection there was a lot of carbonised deposits showing that there must have been a lot of arcing inside. I showed the plug to an electrician who said straight away that the damage was caused by a loose connection inside plug.
I decided to take no chances in the future. No more plugging the car into a multi socket extension. It was going to have its own dedicated lead so I set to ordering all of the components to make up a charge lead . I changed the plug on the car for a new one and ran the new lead from one of the two double sockets in the garage. This was left hanging from the garage roof for easy connection to the car to limit stretch on the Trizy coiled cable.
I posted the photo above on the Twizy facebook page and a chap said he had done a similar thing, but also could monitor the power consumption and activate / deactivate the plug remotely via something called a Fritzbox router.
This looked really interesting but I found that it was only compatible in Europe. However, It didn’t take long to realise that there was a solution for me that would work the same at a fraction of the price. The smart home was always something that I never really wanted to get into, but my research has made me realise that home automation is getting cheaper and cheaper. I’ll cut to the chase as I could start going off on a tangent..
What I ended up buying was a ‘Smart Plug’. This can be controlled via a smart phone via a wifi connection. Very simple setup and the particular model I brought could also monitor power usage
So after watching some youtube footage I thought this looked like it ticked the box. I wasn’t confident at first as this plug would be required to be connected to my wifi network, but this was unfounded. The only issue is that the plug does catch on a regular plugs on / off switch which I thought was a bit of a negative from Teckin. For my case it was fine as it would be sandwiched between the new extension outlet, and the Twizy plug.
Once the smart plug was connected to my wifi network following the guide, I could make the socket live whenever I wanted, monitor the power consumption, set a timer so that it would turn off after a period of time or just turn it off all via my smart phone.
The wheels make a difference on any vehicle and is usually one of the easiest (if not always the cheapest) modification to make. Go on any online portal such as eBay, Demon Tweeks, Google, etc, etc to find a whole raft of possible wheels that will fit the stud pattern of the particular car manufacturer you own. Well you may not be surprised that the Renault Twizy is different. There is quite probably a very good reason for having only 3 studs holding the wheel on, but i can’t really think of one other than it saves the weight of one nut, thus reducing the kinetic energy required for the low powered EV to move and stop along with the cost of one whole stud!
Anyways, I totally get the physics of narrower wheels mean less contact thus reducing friction / drag and as a result increase the range the battery can propel the car. However the Twizy wheels are ridiculously narrow, and this I feel is the one reason that it gets a bad perception from people that can’t handle concepts that fall beyond the norm. For sure there are people that look, stare and point because they think it looks cool in its standard guise, but for all those that stand on the side of the fence that are not quite sure about the Twizy, the wide wheels will be the deciding factor.
So my decision was made that by hook or by crook I was going to put the Burrows touch on the EV. The F1 twizy was inspiration in part, but I had seen other people in the very limited Twizy circle had done some modifications with the wheels. However, the only real route I could go down due to the unique stud pattern was to take the standard steel wheel and have it banded. It’s a process where one side of the rim is cut from the other, they are moved apart the required distance, and a band of metal is welded back in to increase the width. This all sounds very dodgy, but its legal and surprisingly safe.
So i found a chap on a forum that was willing to sell me his old wheels due to the fact he had replaced them with the Twizy stock alloy (equally as narrow as the steel). I sent him the funds and asked him to send the wheels to the banding fabrication company. I liaised with the fabricators (ALONZE CUSTOM FABRICATION – http://www.alonzecustom.co.uk/steel-wheel-banding.php ) about the width of the band i wanted inserting, and within two weeks I had a re-worked set of wheels
The decision was that the rears were going to be different widths. 8 inches at the rear, and 7 front and I was really happy with them when they were returned from the fabricators. The next stage was to have them powder coated. As can be seen by the photo above, there was plenty of bare metal that would would start to oxidise and rust if it got damp, so I made every effort to keep them in a dry environment until they were painted. I decided on a mid grey for the colour. The reason being I didn’t want silver as it was pretty common, I didn’t want black or the similar anthracite as I felt the wheel rim needed to be a different colour to the tyre to separate them.
As you can imagine making a bespoke set of wheels leads you into the territory where you need to get a set of tyres that compliments the wheels and the vehicle they are going to go on. The wrong tyre will have a negative effect on the motors power to get vehicle up to speed, and also an incorrect reading on the speedometer. All of this taken into account I could only source one tyre that would fit both pairs of rims with a rolling radius that would keep the Twizy operating as it should. These were the
Rear: Nankang Ultra Sport NS-2 195/60 R13
Front: Nankang Ultra Sport NS-2 175/60 R13
The cheapest website i could find for the above was 123Tyres at £168 for the full set
After a trip to the local tyre garage the rubber was fitted to the rims. I got the impression it was a little more protracted than usual due to the slightly stretched profile of the tyre on the wheel, but the overall package turned out to be really pleasing .
I was a little concerned that the rim would protrude the rubber with the width I had chosen, but its not. Which is good as far as dinging the rim. I have seen many VW golfs etc with massively over sized wheels and tyres that are stretch ludicrously.
So the next thing was to fit the wheels. I was going to hold off this process due to the fact the mudguards / fenders would need to be removed to accommodate the wheels, which would effectively render the car undrivable during wet weather. However, the temptation got the better of me and I decided to make the change despite this. I’m sure I will regret this in the not too distant future, but at least it will encourage me to get a solution sorted sooner rather than later for a mudguard.
Before I fitted the wheels I couldn’t help but spend a little time cleaning up the running gear and brakes. The front calipers were removed and painted. After a good wire brush down I painted them red. I always find that two coats of hammerite is enough to eat into any corrosion and provide lasting protection for every vehicle i have renovated in the past. This would be no different.
The same was done for the rear, although i decided against painting the calipers as they were in remarkably good condition. I still greased up the handbrake cable and added a small amount of hammerite silver to any rust visible.
As you can see from the image below, its transformed the stature of the vehicle and its stance is much more aggressive. The one thing that lets the Twizy down and turns peoples inquisitivity to err on the side of dislike rather than like, is the puny wheels giving it more of a mobility scooter look than fully fledged road going vehicle.
I will say at this point that I am under no illusion that this modification will have a big impact on performance and range. From a performance point of view I have a solution. I will be fitting a device called a PowerBox (More on this in a future post). This will plug into the ODBC port and will override the Renault restrictions in terms of the power output and speed, effectively doubling the performance. There will be a range reduction but that’s something I am going to have to accept.
This vehicle for me is for primarily for excitement, as has been all of my previous vehicle. It’s a bit odd, but I hope that this will prove there is a new generation of vehicles that can put a smile on peoples faces, much like the Vespa, Lambretta and bubble cars did all those years ago.