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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 2183 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 14438 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 1765 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 2351 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 2738 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 2325 times

Flywheel Mount


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Building the Flywheel Adapter

13 files, last one added on Feb 13, 2009
Album viewed 2673 times

Install Motors


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7 files, last one added on Apr 29, 2009
Album viewed 1731 times

Misc Items


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Miscellaneous parts installed

18 files, last one added on Apr 18, 2010
Album viewed 2725 times

Battery Boxes


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21 files, last one added on May 29, 2009
Album viewed 8375 times

Charging System


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15 files, last one added on May 29, 2009
Album viewed 4762 times

Heater


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3 files, last one added on May 15, 2009
Album viewed 1839 times

12 albums on 1 page(s)

Random files - Ford F250 EV Conversion
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Getting the coupler parts off2498 viewsThen we had to mount each of the motors in the lathe and cut the remaining parts of the coupler off the motor shafts. Being VERY careful to not nick or damage the motor shafts.
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Flywheel adapter work2307 viewsWe continue cutting
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Flywheel adapter boring shaft hole2397 viewsWe start the boring process using a big drill bit.
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Flywheel adapter - oops, hole too big2117 viewsWe didn't read the caliper quite correctly, and accidentally bored the mounting hole for the pilot bearing a bit too big. (20 thousandths or so)
So we brazed in some metal and had to re-do that hole.
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240v charge port2841 views
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Old Heater Core4883 viewsI was really surprised at how easy it was to get the old heater core out of the truck.
Just pop out the glovebox, and remove the panel behind it.
That uncovers the core.
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Ceramic Heater4165 viewsThis shows where it all mounts behind the glove box.
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Truck wiring conduit4598 viewsSome of the DC conduit runs under the truck.

Last additions - Ford F250 EV Conversion
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Decals on back4677 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 cabling6032 viewsThis shows the DC power cableing done - except for the battery boxes themselves.May 29, 2009
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Gauges5993 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 conduit4251 viewsThe conduit for the AC wiring under the truck.May 29, 2009
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Truck wiring conduit4598 viewsSome of the DC conduit runs under the truck.May 29, 2009
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Cables into bed6145 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 Boxes4156 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 truck5668 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