CasaDelGato - Images from the House of the Cat

Last additions
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Old Heater Core4887 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.
May 15, 2009
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Battery Box Fiberglass3724 viewsThis is what the bottom looks like after being fiberglassed with a single layer of fairly heavy chopped mat fiberglass with Epoxy resin.May 15, 2009
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Battery Box Bottom Insulation3691 viewsThe insulation on the bottom of the battery box is permanent, and will be encased in the fiberglass.
It's 2" (1.5" actual) foam board.
May 15, 2009
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Battery Box shaping3709 viewsAs you can see, I had to shape some of the corners to fit the rounded parts of the truck bed.May 15, 2009
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Battery Hold Down mounting4358 viewsBox is upside down. This shows all the flange nuts I put in the bottom for the battery hold downs to bolt into.May 15, 2009
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Battery Hold Downs3413 viewsAll the battery hold down posts are in place. These are 3/8 allthread into the flange nuts on the bottom of the box.
There are posts on either side of each pair of batteries.
A square bar will be across the full width of the box, bolted to all the posts in that row.
May 15, 2009
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Battery Box Mount3095 viewsThere are 2 5/8" bolts at the back of the box to hold the box down to the bed. To keep these from pulling through the wood/fiberglass box, I put a long 1/4" thick steel plate behind each bolt.May 15, 2009
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Battery Hold Down Post Nuts3383 viewsI put a little weld in the bottom of each hold down flange nut so that the post can't be screwed in too far.
This is to prevent it being screwed down through the covering fiberglass at a later date.
May 15, 2009
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Battery Box Mount 3056 viewsThere are 2 more 5/8" bolts at the front of the box, with another steel plate for them.May 15, 2009
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Motor wiring, Series4846 viewsAfter discussing things with several people, I decided to wire the motors in series.
This is because I have a fairly hi voltage page, and should be able to get enough RPM's even with the motors in series.
Also gives much better torque.
May 15, 2009
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Control Wring (part 2)3803 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...
May 15, 2009
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Control Wiring3401 viewsThis is the main control wiring for the EV conversion. It has the Z2K Hairball, and all the various relays, meters, fuses, etc..
The 2 meters are AC Amps and Volts for the PFC-50 charger.
May 15, 2009
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