CasaDelGato - Images from the House of the Cat

Last additions
Old Heater Core5111 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
Battery Box Fiberglass3965 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
Battery Box Bottom Insulation3892 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
Battery Box shaping3921 viewsAs you can see, I had to shape some of the corners to fit the rounded parts of the truck bed.May 15, 2009
Battery Hold Down mounting4568 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
Battery Hold Downs3615 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
Battery Box Mount3299 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
Battery Hold Down Post Nuts3582 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
Battery Box Mount 3259 viewsThere are 2 more 5/8" bolts at the front of the box, with another steel plate for them.May 15, 2009
Motor wiring, Series5056 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
Control Wring (part 2)4018 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
Control Wiring3620 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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