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Remove Gas Drive


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Removing the Gas engine, fuel tanks, etc...

5 files, last one added on Feb 13, 2009
Album viewed 2216 times

Build Motor-Motor mount


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Building the motor-motor mount to hold the 2 Impulse 9 motors together.

9 files, last one added on Feb 13, 2009
Album viewed 14501 times

Motor Coupler 1


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Our 1st attempt at the motor-motor coupler for the 2 Impulse 9 motors.

4 files, last one added on Feb 13, 2009
Album viewed 1801 times

Assemble Motors 1


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Assembling the motors together using version 1 of the motor-motor coupler.

9 files, last one added on Feb 13, 2009
Album viewed 2412 times

Motor Coupler 2


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Our 2nd attempt at the motor-motor coupler.

6 files, last one added on Feb 13, 2009
Album viewed 2800 times

Assemble Motors 2


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Assembling the motors using version 2 of the coupler

8 files, last one added on Feb 13, 2009
Album viewed 2388 times

Flywheel Mount


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Building the Flywheel Adapter

13 files, last one added on Feb 13, 2009
Album viewed 2739 times

Install Motors


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7 files, last one added on Apr 29, 2009
Album viewed 1761 times

Misc Items


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Miscellaneous parts installed

18 files, last one added on Apr 18, 2010
Album viewed 2782 times

Battery Boxes


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21 files, last one added on May 29, 2009
Album viewed 8440 times

Charging System


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15 files, last one added on May 29, 2009
Album viewed 4821 times

Heater


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3 files, last one added on May 15, 2009
Album viewed 1867 times

12 albums on 1 page(s)

Random files - Ford F250 EV Conversion
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Examining the result1989 viewsHere we are looking at the result, and finding that the motors had NOT pressed far enough into the coupler.
We had a 1/2" of extra space to deal with.
We were going to just add a 1/2" spacer, until we did some measuring, and found that the motors were NOT coupled straight. There was a definite wobble.
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Flywheel adapter - finishing with the lathe2297 viewsFinished the lathe work, just needs drilling now.
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2807 viewsShows were the 6 rows and 2 dividers will be.
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Motor Cooling blower2857 viewsThis is the ductwork box I had to build so I can run a hose to each motor.
The box is built out of 3/16" ABS. The blue plate is a metal mounting plate so I can bolt the assembly to the frame.
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PFC-50 location5103 viewsEven with the huge engine compartment that used to hold a 460cui engine, I'm having trouble cramming everything in.
A PFC-50 charger is BIG, and while there is lots of free space, none of it is the right shape for the charger, or there are other things that will be there.
So, it looks like I'll be mounting the charger at the back of the engine bay, behind the battery box, but tilted up so that I can still reach the controls on it.
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Control Wring (part 2)3822 viewsThis is what's under the top board of the control wiring. This is where most of the big parts are located.
PFC-50 plugs, DC-DC converters, fuses for pack voltage accessories, etc...
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Ceramic Heater5563 viewsThis is a 1500W Ceramic Heater mounted where the old Heater core was.
I kept the original overheat switch from the ceramic heater, and added another (at the top) just to be paranoid.
Since I'll be powering it from a 288V pack, I only need to use the center and outer connectors to the core.
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Breaker Boxes4192 viewsThe black box on the left has 3 Airpax 250A DC breakers. These will have a bar bolted to their handles so they all switch together.
The other box has the 2 breakers for the charging system.

Last additions - Ford F250 EV Conversion
DecalsOnBack.jpg
Decals on back4716 viewsI finally got the Decals on the truck.
Hopefully I'll get some good pictures of the ones on the sides as well.
Apr 18, 2010
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DC cabling6068 viewsThis shows the DC power cableing done - except for the battery boxes themselves.May 29, 2009
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Gauges6024 viewsI've mounted 4 gauges on the dash.
Charge Current, Pack Voltage, Battery Current, Motor Current.
May 29, 2009
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Truck wiring AC conduit4284 viewsThe conduit for the AC wiring under the truck.May 29, 2009
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Truck wiring conduit4631 viewsSome of the DC conduit runs under the truck.May 29, 2009
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Cables into bed6183 viewsThis shows how I mounted and protected the cables that run from the front of the truck into the bed.
All under-truck cables are in some kind of conduit, or have a shield between them and the ground.
May 29, 2009
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Breaker Boxes4192 viewsThe black box on the left has 3 Airpax 250A DC breakers. These will have a bar bolted to their handles so they all switch together.
The other box has the 2 breakers for the charging system.
May 29, 2009
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Rear Battery box in truck5698 viewsThis is the rear Battery Box that will hold 42 Golf Cart batteries in the bed of the truck.
(Someday when hitech batteries are reasonably priced, I'll remove this and mount the pack under the bed.)
May 29, 2009