Pulling the engine11064 viewsRemoving the 460cui gas engine. (Having a forklift really made this easier.)
All 762 pounds of it!
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Position motors10151 viewsMotors were mounted to the transmission, then lifted in from below.
Transmission was then bolted to it's mounts, and the motors placed on blocks to keep everything in position
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Battery Box Bottom9891 viewsThis is the bottom of the battery box. It is 3/4" plywood with a 2x2 edge frame.
The colored boxes are pieces of plywood cut to the size of Golf Cart batteries.
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9333 viewsThis shows how there will be 6 batteries across at the back. (there are 8 across at the front)
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Building Motor Mounting Framework9201 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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Motors Installed8609 viewsEverything is in and bolted down. The framework is mounted to the original rubber engine mounts that used to support the 460cui Gas Engine.
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Painted Motor Mount7723 viewsI then sandblasted it all ,and painted it.
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Completed Motor Mount7528 viewsThis is the motor mounting framework, after all the welding was complete.
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Cables into bed6465 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.
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DC cabling6340 viewsThis shows the DC power cableing done - except for the battery boxes themselves.
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Gauges6292 viewsI've mounted 4 gauges on the dash.
Charge Current, Pack Voltage, Battery Current, Motor Current.
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Breaker Box w/mechanical interlock6195 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.
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