Posts Tagged ‘zilla’

High Voltage Wiring

Electronics | Posted by admin June 21st, 2009

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 Trunk

Restoring and Building | Posted by admin May 22nd, 2009

I needed a good dry place to put all of the high voltage components. This includes the Zilla controller, the main contactors, the DC to DC converter, and the charger. The most logical place was in the rear of the car. There isn’t a trunk but there was a nice area just behind the rear suspension that was empty. I decided I would fiberglass in this area with and make a hatch to access it. It would be water tight and away from any road dirt. As an added bonus if done right I might even have enough space to store a small bag or brief case.

The project started by cutting out the hatch with a dremel reinforced cutting wheel being very carefull to make clean straight lines. This was going to be very visible so it needed to be clean looking.

Foam was glued to the inside of the opening to form a lip. Once dried I used a dremel sanding drum to carve out a shape in the lip that would allow for a rubber seal as well as as a trough to carry away any water that came in. This was then fiberglassed.

The floor of the trunk was formed with foam and fiberglassed as well.

The Zilla Controller Arrived

Electronics | Posted by admin February 5th, 2009

The Zilla 1K HV arrived yesterday. I spent the evening reading through the manual. It is a neat little peice of electronics.

The Zilla Controller

technology | Posted by admin January 15th, 2009

Big news came today. Evsource.com emailed me today that my controler is about to ship. The Zilla 1k is a hard to get peice of hardware that is the brains of the car. Though there are other controllers out there, none have the capability of the Zilla controller especially for a DC motor powered sports car.

It’s time to get busy. There is a lot to do to get ready for the controllers arrival. With the brains of the car showing up a moving car isn’t far off in the future. Tonight I study the schematics and start working out the electrical design.