CasaDelGato - Images from the House of the Cat

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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 1779 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 13491 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 1363 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 1657 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 2022 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 1636 times

Flywheel Mount


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Building the Flywheel Adapter

13 files, last one added on Feb 13, 2009
Album viewed 1975 times

Install Motors


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7 files, last one added on Apr 29, 2009
Album viewed 1332 times

Misc Items


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Miscellaneous parts installed

18 files, last one added on Apr 18, 2010
Album viewed 2046 times

Battery Boxes


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21 files, last one added on May 29, 2009
Album viewed 7321 times

Charging System


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15 files, last one added on May 29, 2009
Album viewed 4080 times

Heater


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3 files, last one added on May 15, 2009
Album viewed 1455 times

12 albums on 1 page(s)

Random files - Ford F250 EV Conversion
2009-01-29_15-37-46.JPG
Coupler almost off2479 viewsThis is the coupler when it's just about cut off.
We would cut down to the keyway in the coupler, then we could pry it open just enough to tap it off the shaft.
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Putting them together2642 viewsBoth motors together! Bolted to the motor-motor mount.
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Flywheel adapter - oops, hole too big1679 viewsWe didn't read the caliper quite correctly, and accidentally bored the mounting hole for the pilot bearing a bit too big. (20 thousandths or so)
So we brazed in some metal and had to re-do that hole.
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Building Motor Mounting Framework7196 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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Zilla Mounted1996 viewsA closer view of the Z2K mount
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2328 viewsShows were the 6 rows and 2 dividers will be.
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PFC mount3611 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.
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Charge Port Door switch4520 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.

Last additions - Ford F250 EV Conversion
DecalsOnBack.jpg
Decals on back3680 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 cabling5090 viewsThis shows the DC power cableing done - except for the battery boxes themselves.May 29, 2009
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Gauges4973 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 conduit3323 viewsThe conduit for the AC wiring under the truck.May 29, 2009
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Truck wiring conduit3678 viewsSome of the DC conduit runs under the truck.May 29, 2009
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Cables into bed5146 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 Boxes3466 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 truck4933 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