Flatbed Assembly Plan
Electric Motor—Spec Sheet (80 kW 400 V)
GENERAL DESCRIPTION
Nominal System Voltage: 400 VDC
Operating Voltage Range: 300–450 VDC
Motor Type: PMSM / IPMSM (Permanent Magnet)
Continuous Power: 80–90 kW
Maximum Power (Peak): 140 kW (10–60 s peak)
Parts
Tools
#
MTR-001
Part
Wheel hub
Name
Wheel hub pcd 4x100 + bolts
#
HMTR-001
Part
Mechanics
Name
Torque wrenches: 20–200 nm and 200–600 nm
#
MTR-002
Part
Shock absorbers
Name
2 shock absorbers + hardware
#
HMTR-002
Part
Mechanics
Name
Hydraulic jack + jack stands
#
MTR-003
Part
Swinging arm (swingarm)
Name
2 swinging arms (swingarms)
#
HMTR-003
Part
Mechanics
Name
Hoist / scissor lift table
#
MTR-004
Part
Disc brake axle with rear motor
Name
#
HMTR-004
Part
Mechanics
Name
Ball joint separator (if applicable)
#
MTR-005
Part
Dc motor
Name
400 v 80 kw dc motor controller + hardware + bracket (if applicable)
#
HMTR-005
Part
Mechanics
Name
Manual press (if bushings require pressure)
#
MTR-006
Part
Upper and lower steering columns
Name
2 upper and lower steering columns
#
HMTR-006
Part
Brakes
Name
Brake bleed kit
#
MTR-007
Part
steering wheel
Name
1 steering wheel
#
HMTR-007
Part
Brakes
Name
DOT 4 brake fluid
#
MTR-008
Part
Brake system
Name
#
HMTR-008
Part
Brakes
Name
Brake bleeder wrench
#
MTR-009
Part
Accelerator pedal
Name
1 accelerator pedal
#
HMTR-009
Part
Electrical
Name
CAT III 1000V multimeter
#
MTR-010
Part
gear shifter / gear lever
Name
Gear Shifter (Forward and Reverse)
#
HMTR-010
Part
Electrical
Name
Megger 500V / 1000V
#
MTR-011
Part
Wiring
Name
High-Quality Wiring System
#
HMTR-011
Part
Electrical
Name
Isolated HV Tools (Insulated HV Tools)
#
MTR-012
Part
Wheels
Name
#
HMTR-012
Part
Electrical
Name
Cable Ties + Corrugated Sleeve
#
MTR-013
Part
Support
Name
2 Supports
#
Part
Name
#
MTR-014
Part
Suspensions
Name
2 Suspensions + Hardware (Bolts and Nuts)
#
Part
Name
Assembly Plan
(Motor Kit + Axle + Steering + Brakes)
Steps
Name
Base Specifications
Description
Application: Full Van EV Chassis
- Rear Axle: 1800 mm custom
- Motor: 400V 80kW DC
- Wheel PCD: 4x100
- Brakes: Disc (x4)
Duration
Parts needed
Skills
EV Mechanical Technician HV Electrical Technician LV Electrical Technician QC Inspector
Steps
Step 1
Name
Chassis Preparation
Description
Objective: Prepare the chassis for suspension + rear axle mounting.
- Clean rear and front mounting areas
- Inspect anchor points
- Check threads, drillings, and alignment
- Prepare hardware (bolts/nuts) and tools
Duration
0.30
Parts needed
Skills
EV Mechanical Technician
Steps
Step 2
Name
Support Mounting (2 supports)
Description
Support Mounting (2 supports)
- Install 2 main system supports (brackets)
- Align with the chassis
- Bolt down
- Apply torque + torque marker
Duration
1
Parts needed
MTR-013
Skills
EV Mechanical Technician
Steps
Step 3
Name
Mounting of swingarms (2 pieces)
Description
Duration
1
Parts needed
MTR-001
MTR-003
Skills
EV Mechanical Technician
Steps
Step 4
Name
Suspension Mounting (2 suspensions)
Description
We define 'suspensions' as the suspension assemblies or the control arms and mounts.
Duration
0.45
Parts needed
MTR-014
Skills
EV Mechanical Technician
Steps
Step 5
Name
Shock absorber installation
Description
Duration
1.00
Parts needed
MTR-002
Skills
EV Mechanical Technician
Steps
Step 6
Name
Rear axle mounting with motor and brakes
Description
Critical part of the kit Rear motor disc brake axle (a) 1800 mm width (b) 400V 80kW DC (c) Disc brakes (d) PCD 4x100
- Lift the axle using a jack/hoist
- Align the axle with the swingarms
- Insert main bolts
- Adjust and center
- Final torque
- Confirm the axle rotates freely (no brake drag)
Duration
2.3
Parts needed
MTR-004
Skills
EV Mechanical Technician
Steps
Step 7
Name
Montaje de cubos/bujes de rueda (PCD 4x100)
Description
1-Install left-hand hub 2-Install right-hand hub 3-Confirm PCD 4x100 4-Apply torque 5-Check play (no slack)
Duration
1
Parts needed
MTR-001
Skills
EV Mechanical Technician
Steps
Step 8
Name
Wheel Mounting
Description
Duration
0.30
Parts needed
MTR-012
Skills
EV Mechanical Technician
BRAKE SYSTEM (Mechanical + Hydraulic)
Steps
Step 9
Name
Brake Pedal Installation
Description
Duration
0.30
Parts needed
MTR-008
Skills
EV Mechanical Technician
Steps
Step 10
Name
Brake Hose Installation
Description
Duration
0.45
Parts needed
MTR-008
Skills
EV Mechanical Technician
Steps
Step 11
Name
Brake System Bleeding and Testing
Description
Duration
0.45
Parts needed
HMTR-007
Skills
EV Mechanical Technician QC Inspector
Steps
Step 11
Name
Brake System Bleeding and Testing
Description
Duration
0.45
Parts needed
HMTR-007
Skills
EV Mechanical Technician QC Inspector
Metalwork Assembly Plan - Wortix Full Van EV
- Metal Chassis
- Cabin Cage / Bodywork
- Mounts and Assembly
- Protection and Rigidity
Metalwork Assembly Plan (Chassis + Cage + Brackets + Rigidity)
Steps
Name
Base Specifications
Description
Application: Full Van EV / flatbed, cargo Objective: Manufacture and integrate the metal skeleton ready to receive:
- suspension + drive axle
- battery
- cabin (interiors)
- harnesses and systems
Duration
-
Parts Needed
-
Skills
- Structural Welder Technician
- Assembly / Metalworking Technician
- QC Metrology Inspector (Level B)
- Painting / Protection Technician (Level B)
Steps
Step 1
Name
Steering Wheel Installation
Description
Objective: Avoid errors in parts, lengths, and positioning
- Identify all parts by code
- Review thicknesses and material (tube / sheet)
- Mark the center of the chassis (line 0)
- Prepare jig / template and reference points
Duration
1
Parts needed
MTL-001 MTL-002 MTL-003 MTL-004 MTL-005 MTL-006 MTL-007 MTL-008 MTL-009 MTL-010 MTL-011 MTL-012 MTL-013 MTL-014 MTL-015 MTL-016
Skills
- Assembly / Metalworking Technician
- QC Metrology Inspector (Level B)
Steps
Step 2
Name
Chassis base assembly (stringers + crossmembers)
Description
- Place 2 longitudinal stringers on jig
- Align and measure diagonals (X)
- Place front crossmembers
- Place central crossmembers
- Place rear crossmembers
- Tack weld all points
- Re-verify diagonals and squareness
- Final welding by sequence (anti-deformation)
Duration
6
Parts needed
MTL-001 MTL-002 MTL-014
Skills
- Structural Welder Technician
- Assembly / Metalworking Technician
- QC Metrology Inspector (Level B)
Steps
Step 3
Name
Front subframe installation
Description
Objective: Prepare the area where steering + front suspension will be mounted.
- Position front subframe on jig
- Align with the chassis center axis
- Tack weld
- Measure heights and level
- Final welding
Duration
4
Parts needed
MTL-003 MTL-014
Skills
Técnico Soldador Estructural Técnico Armador / Metalmecánico
Steps
Step 4
Name
Rear subframe installation
Description
Objective: Prepare the area where the drive axle will be mounted.
- Position rear subframe
- Verify distance between suspension points
- Tack weld
- Review diagonals
- Final welding
Duration
4
Parts needed
MTL-003 MTL-014
Skills
- Structural Welder Technician
- Assembly / Metalworking Technician
- QC Metrology Inspector (Level B)
Steps
Step 5
Name
Battery tray / pack support structure
Description
Objective: Structural assembly for the battery pack (critical zone).
- Place tray in position
- Verify:
- ground clearance
- fixing points
- maintenance access
- Tack weld
- Weld by sequence
- Install local reinforcements
Duration
5
Parts needed
MTL-009
Skills
- Structural Welder Technician
- QC Metrology Inspector (Level B)
Steps
Step 6
Name
Motor / powertrain mounts
Description
Objective: Prepare the points for mounting the motor/axle kit.
- Position motor mounts (according to the plan)
- Verify height and alignment
- Tack weld
- Final welding
- Check that it does not interfere with the battery tray
Duration
3
Parts needed
MTL-010 MTL-014
Skills
- Structural Welder Technician
- Assembly / Metalworking Technician
Steps
Step 7
Name
Control arms / suspension links (points)
Description
ALERT: metal mounting points are manufactured/installed here.
- Position control arm brackets
- Verify left/right symmetry
- Tack weld
- Final welding
- Measure distance between points
Duration
4
Parts needed
MTL-012 MTL-014
Skills
- Structural Welder Technician
- QC Metrology Inspector (Level B)
CABIN CAGE / BODYWORK
Steps
Step 8
Name
Cabin floor (floor panel)
Description
Objective: Create the cabin base and cargo area.
- Present floor panel on chassis
- Align with center and reference points
- Tack weld on edges
- Weld bead by sections
- Seal joints (if applicable)
Duration
3
Parts needed
MTL-007 MTL-015
Skills
- Structural Welder Technician
- Assembly / Metalworking Technician
Steps
Step 9
Name
Installation of pillars A / B / C
Description
Objective: Assemble the vertical cage.
- Mount left and right A-pillars
- Verify inclination and symmetry
- Mount B-pillar
- Mount C-pillar
- Complete tack welding
- Measure cabin diagonals
- Final welding
Duration
5
Parts needed
MTL-005 MTL-015
Skills
- Structural Welder Technician
- QC Metrology Inspector (Level B)
Steps
Step 10
Name
Roof panel
Description
Objective: Close the upper structure and provide rigidity.
- Present roof panel
- Align with pillars
- Tack weld perimeter
- Weld by sequence (to prevent deformation)
- Check for waviness
Duration
3
Parts needed
MTL-004 MTL-015
Skills
- Structural Welder Technician
- Assembly / Metalworking Technician
Steps
Step 11
Name
Side panels / body panels
Description
Objective: Close sides and provide shape.
- Present left side panel
- Present right side panel
- Align with pillars
- Tack weld
- Final welding (or rivet if design allows)
- Verify symmetry
Duration
6
Parts needed
MTL-008 MTL-015
Skills
- Structural Welder Technician
- Assembly / Metalworking Technician
- QC Metrology Inspector (Level B)
Steps
Step 12
Name
Door assembly (metal structure)
Description
Objective: Prepare doors for subsequent hardware installation.
- Assemble door interior structure
- Join exterior panel
- Verify:
- alignment
- perimeter gap
- Tack weld
- Final welding
- Check for warping
Duration
8
Parts needed
MTL-006 MTL-015
Skills
- Structural Welder Technician
- Assembly / Metalworking Technician
PROTECTION AND RIGIDITY
Steps
Step 13
Name
Reinforcement plates / lower panels
Description
Objective: Rigidity + impact and torsion protection.
- Install plates in:
- sides
- subframe joints
- battery zone
- Tack weld
- Final welding
- Check that it does not interfere with harnesses
Duration
4
Parts needed
MTL-013
Skills
- Structural Welder Technician
- QC Metrology Inspector (Level B)
Steps
Step 14
Name
Seat frames
Description
Objective: Secure structure for driver and passenger.
- Position frame
- Verify ergonomics (height and distance)
- Tack weld
- Final welding
- Verify level
Duration
2
Parts needed
MTL-011
Skills
- Structural Welder Technician
- Assembly / Metalworking Technician
Steps
Step 15
Name
Weld finishing + surface preparation
Description
Objective: Prepare for anti-corrosive painting.
- Grinding of weld beads (where applicable)
- Removal of burrs
- Cleaning with degreaser
- Visual inspection of welds
Duration
4
Parts needed
Skills
- Assembly / Metalworking Technician
- QC Metrology Inspector (Level B)
Steps
Step 16
Name
Anti-corrosive protection + sealing
Description
Objective: Protect the chassis and bodywork against oxidation.
- Apply epoxy primer
- Apply seam sealer to joints
- Paint or coating
- Controlled drying
Duration
6
Parts needed
Painting consumables
Skills
- QC Metrology Inspector (Level B)
- Painting / Protection Technician (Level B)
Name
Critical points (most frequent causes of rework)
Description
- Chassis diagonals out of tolerance
- Misaligned A/B/C pillars (doors do not close)
- Welding deformation on roof and side panels
- Misplaced battery tray (pack does not fit)
- Non-symmetrical suspension points
- Lack of reinforcement in subframe joints
Duration
68
