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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 1791 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 13531 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 1376 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 1679 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 2046 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 1656 times

Flywheel Mount


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Building the Flywheel Adapter

13 files, last one added on Feb 13, 2009
Album viewed 2000 times

Install Motors


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7 files, last one added on Apr 29, 2009
Album viewed 1346 times

Misc Items


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Miscellaneous parts installed

18 files, last one added on Apr 18, 2010
Album viewed 2072 times

Battery Boxes


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21 files, last one added on May 29, 2009
Album viewed 7406 times

Charging System


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15 files, last one added on May 29, 2009
Album viewed 4107 times

Heater


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3 files, last one added on May 15, 2009
Album viewed 1470 times

12 albums on 1 page(s)

Random files - Ford F250 EV Conversion
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Boring coupler shaft holes1591 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.
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Motor-Motor mount body1617 viewsAnd a piece of old iron pipe from the same place.
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1711 viewsAll walls installed.
Note that all wood-wood mounting is by gluing them together, and then using deck screws as well.
TruckPackSystem.jpg
Pack Voltage System Schematic4995 viewsThis is the schematic for the Hi Voltage DC System.
It includes everything that connects to the pack.
I've left out a few of the hairball connections (like tach and tach sensor) that don't connect to anything else.
(Done with EagleCAD)
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240v charge port2345 views
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Charge Port Door switch4526 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.
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Battery Box shaping3211 viewsAs you can see, I had to shape some of the corners to fit the rounded parts of the truck bed.
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Old Heater Core4170 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.

Last additions - Ford F250 EV Conversion
DecalsOnBack.jpg
Decals on back3685 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 cabling5095 viewsThis shows the DC power cableing done - except for the battery boxes themselves.May 29, 2009
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Gauges4978 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 conduit3329 viewsThe conduit for the AC wiring under the truck.May 29, 2009
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Truck wiring conduit3684 viewsSome of the DC conduit runs under the truck.May 29, 2009
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Cables into bed5152 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 Boxes3472 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 truck4939 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