Skoda Octavia Estate 2001

[Kevin Sharpe]

I'll have to see how to wrangle funds around that if that is what I have to do and look at the motor options.

You really need to decide what your budget is for the conversion. Without that figure this is all guess work. Tell us the maximum you can spend on parts and we'll tell you what you can get for that money

[Jack Bauer]

I gave up giving parts to people quite some time ago as they all ended up rotting away while the person concerned cryed in their teacup about how hard it was to build an ev. I've know you for some time so I know that won't happen. I have quite a few components here including batteries that I need to move on as 1)I'm loosing storage space soon and 2)I'm never going to use. So, If you undertake to share your build here and arrange collection / shipping I will give you the bits you need to get moving.

Available are :

-Prius Gen 2 transaxle with welded power split device to allow mg1 and mg2 propel the vehicle.
-Drive shafts to fit.
-Gen 2 inverter with controller.
-Yaris inverter with logic board to use as a charger.
-Valance 18v lifepo4 batteries soon to be removed from the E65.
-Random wire, contactors, switches and fuses.
-Zafira power steering pump and hydraulic fittings.
-Choice of a few old android phones to use as a display in car.

[Maker_of_Things]

If you undertake to share your build here and arrange collection / shipping I will give you the bits you need to get moving.

You're on!
Thank you!

With a component list like that I know where I stand and what goes, and what stays.
I can get on with pulling the engine and trans and crap, and making space for the parts you have.

Would you be able to put it all on a pallet, or should I plan a trip over to pick up?
Thank you.

[Jack Bauer]

Pallet is no problem or you are welcome to collect. Whichever suits.

[Maker_of_Things]

Thank you, I will work something out. Can you message me your address please and I can start costing and planning please.

Do you have a deadline to get it out of the way?

Thank you.

[Jack Bauer]

pm sent

[JaniK]

Very good community spirit here! Thumbs up!

[Jack Bauer]

Inverter and transaxle with welded power split gear. Also have halfshafts. Also some random power tools and a 12v battery. full 400v pack of valance lifepo4 batteries. More as I find stuff.

[Maker_of_Things]

That is great stuff!

I will be in touch, thank you.

[Jack Bauer]

My pleasure and no worries. Have found a few more bits today. Set of bmw contactors, type 2 charge cable.

[Maker_of_Things]

Right, first things first!

I need to reorganise the drive.
It is a narrow drive sloping down to the entrance gates and is a cobble surface, not an ideal surface for trolley jacks, axle stands, and engine cranes to operate on. So I will need to pull two trailers off the drive and put the Octavia in bonnet first to the top end under the car port.

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But before that I also need to extend the paving slabbed area at the top end to at least as far as the end of the car port.

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I do have some slabs ready so I just need to move other project stuff out the way and get on with putting slabs down in preparation for the move around. The front of the car will only be part way under so as long as it is enough to get the crane in safely then that should be ok.

Current mileage is 241027 miles.

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I have also started a blog on my website with a little more information. Link in my signature below.

[celeron55]

You don't need to host images for this forum. It's recommended to use the upload functionality so that images aren't lost due to external servers going down.

[Maker_of_Things]

You don't need to host images for this forum. It's recommended to use the upload functionality so that images aren't lost due to external servers going down.

Ahh, thank you. I couldn't find where to upload them at the time and as I have a website where I'd be blogging anyway I thought it I'd do it that way.

[Jack Bauer]

Before tearing out the engine and gearbox can you measure the distance between the half shaft flanges? One thing I like about vw is how they use bolt on half shafts. I'm going to get my driveshaft guy to adapt the prius inner cv cups to vw flange but we'll need to know the gap between them on the stock gearbox. That way its a drop in fit for the skoda gearbox at least in the halfshaft sense.

[Maker_of_Things]

Before tearing out the engine and gearbox can you measure the distance between the half shaft flanges? One thing I like about vw is how they use bolt on half shafts. I'm going to get my driveshaft guy to adapt the prius inner cv cups to vw flange but we'll need to know the gap between them on the stock gearbox. That way its a drop in fit for the skoda gearbox at least in the halfshaft sense.

Thank you, I will see what I can do. I can't get under the car safely at the moment due to uneven and loose cobbles hence needing to reorganise the driveway and trailers and stuff first. But I can see what I can do safely.

So what you want me to measure is the distance, flange face to flange face, of the stock gearbox when the driveshafts are removed.
I will make up a set of parallel calipers.

[Jack Bauer]

A measuring tape will be fine. as long as its within say 5mm the cv joints will take up the slop.

[bexander]

I do not know the distance on the Skoda or which gearbox it used but if you wan't to use the VW half shaft, see attached pdf for some useful info.

VW_drive_shaft_length.pdf

Distance flange-to-flange on a 010 (automatic) gearbox is 226mm and according to the drive shaft length it should be the same for a 020 gearbox.
The 020 is used in a hole lot of VW:s.

[Maker_of_Things]

Oh heck, I gotta measure the CV flange distance!

With a bit of an unsafe faff, lifting each side in turn to get axle stands underneath, I managed to get the car up in the air on the stands, on loose and wobbly cobbles, and then gave it a good push and shake.

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Satisfied it wasn't going to fall on me immediately I shoved it again and then got underneath.

The engine undertray then came off, three different types of screw fixings and a load of cable ties were holding it in place. I will revisit that when everything else is done and see if I can do a better job of it.

Anyway, with a light and a phone under the car, I found the CV joints and figured out how I could get a reasonably accurate measurement of the flange spacing.

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I got some scraps of stick from the workshop bin and, with a couple of small G cramps, I made a simple caliper.

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Back under the car I managed to get the caliper points to touch off on the rim of the CV flanges.

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I was then able to Shuffle back out and put a tape measure across the caliper points.

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248mm it seems, probably something like 245mm face to face ignoring the raised location rim.
I guess that is within the 5mm that is required

[bexander]

248mm it seems, probably something like 245mm face to face ignoring the raised location rim.
I guess that is within the 5mm that is required.

On the flanges that have an inside diameter of 90mm the raised location rim is 3,5mm high so total 7mm to be removed. However, it is proably the 100mm flanges on this car as on most modern VW:s and I do not know if they are the same.

[jap]

Octavia mk1 should be related to mk4 golf platform, so gearbox is likely 02J.family. Flanges should be 108mm, for shorter shafts I'm not too convinced that older stuff has proper splines for joints on either end? But anyways there should be tons of seats, audis, skodas etc. with 02J boxes and different track widthts on scrapyards to go through.

E: I see there is also two types of inner joint to mix things up. Might be useful start to find a generic part number for an inner cv and look what else it fits.

E2: https://shop.febest.eu/inner-cv-joint-3 ... -5021.html

Likely these? Couldn't find 108mm joints for mk1 Octavia, doesn' t mean that they don't exist

[Maker_of_Things]

On the flanges that have an inside diameter of 90mm the raised location rim is 3,5mm high so total 7mm to be removed. However, it is proably the 100mm flanges on this car as on most modern VW:s and I do not know if they are the same.

So possibly allowing for errors 240mm seems a sensible face to face measurement, though there probably isn't a reason for it to be a nice round number.

Should I measure the CV joint diameter just to be complete?

[Maker_of_Things]

I just set a bow caliper to 100mm and reached in under the bonnet to the CV joint.

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And it is 100mm.

[Jack Bauer]

Perfect thanks.

[Maker_of_Things]

Just a quick one.
I have started the driveway tidy and loaded up a pair of Citroen 2CV axles, complete with driveshafts and suspension, and a caravan axle. these might be saleable. I also stripped down a big range cooker and an electric hospital bed, both of which will be a good source of steel stock that might come in useful for the conversion. Saves buying it in new for brackets and folded boxes.

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There is a load more stuff to sort out and then I can pull the trailers out and move the Skoda up the drive where it will be easier and safer to start the conversion.
Also no point having an immobile car blocking the drive for getting the trailers out.

I know some of this will be tedious and boring pre conversion stuff, so I will keep these posts brief, with more detail in my blog for the strange people who are really interested in the background slog.

[Maker_of_Things]

I dismantled my electric tractor to make space for the car conversion...

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Almost got it all apart and put away but the rain started.
Full write up on my blog.