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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 2580 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 14927 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 2142 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 2825 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 3220 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 2810 times

Flywheel Mount


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Building the Flywheel Adapter

13 files, last one added on Feb 13, 2009
Album viewed 3159 times

Install Motors


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7 files, last one added on Apr 29, 2009
Album viewed 2075 times

Misc Items


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Miscellaneous parts installed

18 files, last one added on Apr 18, 2010
Album viewed 3197 times

Battery Boxes


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21 files, last one added on May 29, 2009
Album viewed 8864 times

Charging System


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15 files, last one added on May 29, 2009
Album viewed 5221 times

Heater


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3 files, last one added on May 15, 2009
Album viewed 2158 times

12 albums on 1 page(s)

Random files - Ford F250 EV Conversion
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Exhaust system4281 viewsExhaust system from the F250. 117 pounds, 14' long.
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Starting the 1st version of the Motor Coupler4935 viewsHere we are starting work on the first version of the coupler to connect the 2 Impulse 9" motors.
This is going to be a single piece coupler that press-fits on both shafts.
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2nd motor 2362 viewsThen we quickly lowered the 2nd motor down into the coupler, and once again had to do some pounding.
Another bad sign.
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Flywheel adapter - finishing it up2540 viewsWe've cleaned up the pilot bearing hole, and are finishing the surface to the thickness needed.
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Motor-Motor mount test fit2576 viewsHow it fits on one of the motors.
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Building Motor Mounting Framework9518 viewsWe decided it was easiest to juts build the motor mounting framework in place. Carefully cut pieces and clamp them in place, then tack weld it all together.
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Zilla Mounted4244 viewsThis shows where the Z2K Controller is mounted.
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Breaker Box w/mechanical interlock6266 viewsThis is the breaker box that is mounted on the truck. It has a 240V, 50A GFCI breaker, and a 20A 120V (dual) breaker.
Each breaker enables one of the charge ports. Only 1 can be "on" at a time due to the rather simple mechanical interlock.

Last additions - Ford F250 EV Conversion
DecalsOnBack.jpg
Decals on back5152 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 cabling6505 viewsThis shows the DC power cableing done - except for the battery boxes themselves.May 29, 2009
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Gauges6472 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 conduit4738 viewsThe conduit for the AC wiring under the truck.May 29, 2009
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Truck wiring conduit5055 viewsSome of the DC conduit runs under the truck.May 29, 2009
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Cables into bed6629 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 Boxes4624 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 truck6121 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