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Top rated - Ford F250 EV Conversion
2009-05-15_15-06-52.JPG
120V, 20A charge port3794 viewsAs you can see, it has the sideways prong to only allow a 20A rated cord to plug into it.
I'll carry an adapter for those times I need to plug into a 15A or less outlet.
55555
(1 votes)
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Charge Port Door switch5478 viewsThis shows how I mounted a switch on each of the charge port doors. (used to be gas tank doors!)
This switch will tell the Z2K controller if either of the charge port doors is open, and if so, it won't let the truck "start".
Really helpful to prevent driving off with the cord still plugged in.
55555
(1 votes)
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PFC mount4645 viewsThis shows how the PFC 50 charger is mounted under the hood.
It's at an angle so that I can easily reach the controls.
The 2 meters in the wiring station are a 50A AC Ammeter, and a 300V AC Voltmeter. Useful for adjusting the charger for whatever I happen to be plugged in to.
55555
(1 votes)
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Breaker Box w/mechanical interlock6207 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.
55555
(1 votes)
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Motors Wired4200 viewsI wired the motors to the Z2K using 4/0 cable.
Notice that I don't like exposed High Voltage connections. Couldn't do much about the 1000A shunt though.
55555
(1 votes)
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Motors Installed8640 viewsEverything is in and bolted down. The framework is mounted to the original rubber engine mounts that used to support the 460cui Gas Engine.55555
(1 votes)
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Position motors10192 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
55555
(1 votes)
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Pulling the engine11098 viewsRemoving the 460cui gas engine. (Having a forklift really made this easier.)
All 762 pounds of it!
55555
(1 votes)
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Flywheel and cluth mounted3559 viewsBolted things together, bolted on the flywheel and clutch assemblies.
55555
(1 votes)
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Motor and Transmission4171 viewsHere is the full drive assembly. Both Impulse 9 motors, transmission and transfer case.
We are going to lift it into the truck from the bottom.
55555
(1 votes)
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Flywheel adapter is on!3723 viewsCooling it down after pressing it on to the shaft. (more like setting it on, and tapping it gently down.)
55555
(1 votes)
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Bolting coupler together3695 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.
55555
(1 votes)
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