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Random files - Ford F250 EV Conversion
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.
Uncoupling the motors2421 viewsSo, we tried heating and prying to get the motors apart.
Nope, isn't going to work.
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.
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.
Zilla Mounted4226 viewsThis shows where the Z2K Controller is mounted.
2398 viewsAll walls installed.
Note that all wood-wood mounting is by gluing them together, and then using deck screws as well.
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
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
DC cabling6429 viewsThis shows the DC power cableing done - except for the battery boxes themselves.May 29, 2009
Gauges6391 viewsI've mounted 4 gauges on the dash.
Charge Current, Pack Voltage, Battery Current, Motor Current.May 29, 2009
Truck wiring AC conduit4662 viewsThe conduit for the AC wiring under the truck.May 29, 2009
Truck wiring conduit4986 viewsSome of the DC conduit runs under the truck.May 29, 2009
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
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
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
