Archive for September, 2009

Turning it on

Uncategorized | Posted by admin September 27th, 2009

Worked all day tying up loose ends connecting up the last few switches and wires. Hooked up the car computer to the Zilla and got the whole system ready to power up. After doing one last check of all the wiring and making sure no tools were in the battery compartment, the time was here to turn the key. My son and I jacked up the back and put in the jack stand so the rear wheels were off the ground. The front wheels were blocked off.

I turned on the main aux battery power. The Zilla controller came to life with a green light. I pulled up hyperterminal on the computer and hit connect. Moments later I was rewarded by the Zilla giving me a menu. Sucess!

Now time to connect up the battery pack. With my son Andy at the computer it was time to turn on the key and see if the main contactor would engage. I got in the drivers seat and turned the key. There was a click and then a red warning light. The Zilla was registering an error. Shut down.

I looked over the system but didn’t see anything out of place. Time to call a friend. I put in a call to Lowel Simmons and left him a voicemail. A few moments later I got a call from Lowel. He walked me through the setup screens in the Zilla. They were not all set up. Made a few changes and powered up again. Turned the key and click. The main contactor came on line. The computer read 1314 status code. A quick check of the manual confirmed a 1314 code as a ready to go, waiting for the accelorator pedal. All green lights.

I got in the car seat and pressed the pedal. Nothing. Disapointment…and a call to come in for diner. Looks like tomorrow night I begin checking wires.

So close.

Creating an air intake for the controller radiator

Electronics | Posted by admin September 25th, 2009

The Zilla DC motor controller is a liquid cooled system.  It uses a small radiator to cool the coolant which is pumped through the system.  I wantd to create an air intake and duct system to help cool this system.  Though it will also have a small fan, hopefully I won’t need it.

The GT body already had air scoops designed in the body.  One of these was cut out for this use.  A duct then needed to be fabricated to match up to this air intake and transfer air to the square radiator.  This I fabricated out of fiberglass.

Step 1 was to create a cardboard mold. This mold was covered in duct tape and fiberglass cast over the top of it.  Below you can see the mold on the right and the fiberglass peice on the left.

2. Sand the peice and add a little filler to make it look more finished.

3. The radiator is bolted onto the duct.

4.Bolts were fiberglassed into the body to attach the duct over the air scoop.

5.A mount was also fiberglassed in to hold the pump.

The High Voltage Components are Installed

Restoring and Building | Posted by admin September 25th, 2009
The Motor controller

The Motor controller

Once everything was wired on the high voltage board, it was time to install it into the trunk compartment of the car and hook everything up.

Hooked up

Zilla controller access through the trunk

trunk access