With the batteries here it’s time to start working on the high voltage wiring. Unlike the normal car power which is 12 volt and grounded to the frame, the high voltage traction power must be isolated. Because of the high amperage all of the wiring will be 2/0 electrical cable.
The first part was to map out where all the batteries are going to go and how the current will be routed. The positive ends need to be next to the negative ends so they can be easily routed with the least amount of wire. 2/0 cable is expensive stuff so measuring well will save money.
The cables all get connected with wiring lugs. These are crimped on with a special hammered crimper. You have to be carefull when you strip the ends not to cut any of the small strands that make up the cable. You also need to be carefull when putting on the lug that all of the strands fit nicely inside. A good wack on the little crimping device with a large hammer makes a good strong joint. The ends are then shrink wrapped with shrink tubing to keep out moisture.
The next step was to look closely at the wiring diagrams provided by Cafe Electric for the Zilla controller. I redrew their diagram to better fit the placement of my components in my car. This excersize also helped in my understanding of the logic and how the system would work. I am going to use two contactors. The main contactor is a Tyco Kilovac. I want to be able to go in reverse without shifting so I am using a special reversing contactor that is actually a dual contactor. This will reverse the field on the motor with the flip of a switch.
The Warp 9 motor is lowered into the car for the first time.
It took taking it in and out a few times and making adjustments to the motor mount rails to get the motor perfectly lined up.
The motor is in place and lines up with the shaft. Angle Iron is cut and drilled to bolt into the motor face. Once the coupler arrives and everything fits, holes will be drilled and these brackets will be bolted in place.
Here the coupler is in place.
A close up of the great bracket that Lowell Simmons machined for me. I met Lowell at the Florida EAA (Electric Auto Association) and he has been a great resource. He teaches a shop class to some local high school kids and has them doing electric conversions on cars and even drag racing them. One of his kids recent projects, a Porsche, was faster off the line than a Tessla at the 2009 Battery Beach Burnout. Its going to be interesting to see what his students end up building once they graduate.
This end is actually my old clutch plate machined down and inserted in. Great job.
With the coupler in place, the rest of the bracket was fabricated, painted, and bolted in place.
The wires on the motor were rigged up to test the motor. (These will be replaced with larger cable before the car is running on full battery pack.) The motor was tested by hooking a 12 volt battery directly to the motor with the car up on jack stands. Everything ran great and had a really cool electric whine. Can’t wait to get the whole traction battery pack installed with the Zilla controller.
Fabrication of the motor mount for the Warp 9 electric motor.
This mount replaces the clutch bell housing and keeps the motor in line with the drive shaft. The motor will sit in this frame and be strapped in. There is a face plate which the motor also bolts into which will be welded in place once the motor is connected to the shaft and the alignment is perfect.
--- On Wed, 11/4/09, Bob Rice wrote: > I want to get an AIRPLANE propeller, hook it > up to a 9" motor, Hey Bob... A lot has been happening over 2008/2009 with props spun by electrical batts... Bit of a round up here: http://endless-sphere.com/forums/viewtopic.php?f=7&t=3670tks Loc ______________________________________________________ […]
On 4 Nov 2009 at 10:14, Bob Rice wrote: > Anybody tried those hi freq rodent noise gadgets, that they SAY will > run critters off? THAT would seem to be the answer, left on in the > Electrc Storage area, etc? I put one of those gadgets, a cheapie, in the garage years ago, for the exact reason we're discussing here - mice like making their hom […]
----- Original Message ----- From: "joe" To: "Electric Vehicle Discussion List" Sent: Wednesday, November 04, 2009 10:22 AM Subject: Re: [EVDL] Of Men and Mice,musings an' stuff > Bob, try peanut butter as bait in the mouse trap - they can't resist it! > I've also used chocolate with good results. My mom uses pumpk […]
I call bs on the weight claim, at the very least its going to add about 6-8lbs I think this is a hype product that could be an easy sell to companies that already provide vehicle wraps (like the one I work for) I wonder if is printable ? It almost looks like the perforated film for back windows applied all over the car. I really question the effectiveness of […]
Bob, try peanut butter as bait in the mouse trap - they can't resist it! I've also used chocolate with good results. My mom uses pumpkin or squash seeds. BTW, we have 7 cats; and mice still all over the place; the EV's make a safe home for them where the cats can't get them!! Joseph H. Strubhar Web: www.gremcoinc.com E-mail: joe@... -- […]
What IS it with Electrac's anyhow!?? Do they COME with mice built in? NEVER met one that wasn't FULL of mouse stuffings, exhaust, and debris?!In my morabund collection of Electracs, they are a mouse colony! My Sentra, abuilding, has been in the GARAGE, albiet an non attached one, pulled it out in the sunlight and the glove box was FULL of mo […]
Hi all - I am still researching LiFePO4 BMSs that will work with my (soon-to-be) 144V lithium pack and existing PFC-20 and Z1K-HV. I have heard about EV Works' BMS-MCU-TS90-EV2 control unit. Seems reasonably inexpensive, and achieves balancing with its associated cell modules: http://www.evworks.com.au/index.php?product=BMS-MCU-TS90-EV2Who has worked w […]
David, IIRC my FR Charger has a plate and toggle switch on the front to change from 110 to 220 input, you just take the plate off and reverse it which locks the toggle in the other position. Regards, David Chapman. --- On Tue, 11/3/09, David Roden wrote: From: David Roden Subject: Re: [EVDL] Fair Radio Charger. Remember them? To: "Electric Vehicle Dis […]
I highly recommend the windup traps. They can catch several mice at once and it's much easier to get the mice out of. Once I catch some mice, I just pop the whole thing in the freezer. That turns them into "mousicles". Since my wife feeds birds of prey, that's perfect; bite-size morsels. Someone without a specific "bird food free […]
On 3 Nov 2009 at 23:24, web@... wrote: > Today you pointed out that you did indeed ask questions about the Elithion > system, some time back, but you did so here, in the EVDL. If you feel that we > should be on top of that, and answer all questions that may appear on line > somewhere, then you are right, and I apologize. Please forgive me for ste […]
