3 files, last one added on May 15, 2009 Album viewed 1470 times
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Random files - Ford F250 EV Conversion
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.
Motor-Motor mount body1617 viewsAnd a piece of old iron pipe from the same place.
1711 viewsAll walls installed.
Note that all wood-wood mounting is by gluing them together, and then using deck screws as well.
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)
240v charge port2345 views
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.
Battery Box shaping3211 viewsAs you can see, I had to shape some of the corners to fit the rounded parts of the truck bed.
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
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
DC cabling5095 viewsThis shows the DC power cableing done - except for the battery boxes themselves.May 29, 2009
Gauges4978 viewsI've mounted 4 gauges on the dash.
Charge Current, Pack Voltage, Battery Current, Motor Current.May 29, 2009
Truck wiring AC conduit3329 viewsThe conduit for the AC wiring under the truck.May 29, 2009
Truck wiring conduit3684 viewsSome of the DC conduit runs under the truck.May 29, 2009
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
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
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