CasaDelGato - Images from the House of the Cat

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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 2521 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 14869 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 2087 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 2768 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 3164 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 2749 times

Flywheel Mount


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Building the Flywheel Adapter

13 files, last one added on Feb 13, 2009
Album viewed 3096 times

Install Motors


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7 files, last one added on Apr 29, 2009
Album viewed 2022 times

Misc Items


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Miscellaneous parts installed

18 files, last one added on Apr 18, 2010
Album viewed 3137 times

Battery Boxes


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21 files, last one added on May 29, 2009
Album viewed 8805 times

Charging System


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15 files, last one added on May 29, 2009
Album viewed 5160 times

Heater


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3 files, last one added on May 15, 2009
Album viewed 2104 times

12 albums on 1 page(s)

Random files - Ford F250 EV Conversion
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Boring coupler shaft holes2219 viewsThis time we wanted to be SURE our boring bar wouldn't flex, so we built a much stronger one.
We also are using much better cutting tips.
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Uncoupling the motors2421 viewsSo, we tried heating and prying to get the motors apart.
Nope, isn't going to work.
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Coupler almost off3271 viewsThis is the coupler when it's just about cut off.
We would cut down to the keyway in the coupler, then we could pry it open just enough to tap it off the shaft.
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Bolting coupler together3724 viewsWe hadn't realized just how difficult it was going to be to tighten the bolts holding the coupler together. It was really awkward and hard. Took 2 people. (one turning the motor, the other holding the allen wrench.)
This was compouned when we discovered another alignment problem. Turns out that the end bells of the Impulse 9 motors aren't that accurately machine. We had a 10-20 thousandths variance between them that we had to shim.
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Flywheel adapter work2508 viewsWe continue cutting
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Zilla Mounted4226 viewsThis shows where the Z2K Controller is mounted.
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2398 viewsAll walls installed.
Note that all wood-wood mounting is by gluing them together, and then using deck screws as well.
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Mechanical link between Breakers3707 viewsThis shows how I made it so that only 1 of the 2 power inlet breakers can be ON at a time.
Both can be off, but only 1 can be ON.

Last additions - Ford F250 EV Conversion
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Decals on back5078 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 cabling6429 viewsThis shows the DC power cableing done - except for the battery boxes themselves.May 29, 2009
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Gauges6391 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 conduit4662 viewsThe conduit for the AC wiring under the truck.May 29, 2009
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Truck wiring conduit4986 viewsSome of the DC conduit runs under the truck.May 29, 2009
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Cables into bed6559 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 Boxes4558 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 truck6059 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