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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 1862 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 13779 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 1439 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 1795 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 2170 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 1774 times

Flywheel Mount


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Building the Flywheel Adapter

13 files, last one added on Feb 13, 2009
Album viewed 2108 times

Install Motors


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7 files, last one added on Apr 29, 2009
Album viewed 1415 times

Misc Items


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Miscellaneous parts installed

18 files, last one added on Apr 18, 2010
Album viewed 2176 times

Battery Boxes


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21 files, last one added on May 29, 2009
Album viewed 7738 times

Charging System


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15 files, last one added on May 29, 2009
Album viewed 4227 times

Heater


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3 files, last one added on May 15, 2009
Album viewed 1540 times

12 albums on 1 page(s)

Random files - Ford F250 EV Conversion
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Bolting coupler together3009 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.
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Motor Shroud for Blower4572 viewsThis is the shroud I wrap around each motor (Brush end) to connect the ductwork from the blower.
It's made out of 4" wide aluminum flashing. Just cut with a carpet knife, and flex the cuts apart.
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Motor Cooling blower2416 viewsThis is the ductwork box I had to build so I can run a hose to each motor.
The box is built out of 3/16" ABS. The blue plate is a metal mounting plate so I can bolt the assembly to the frame.
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Blower Mounted2124 viewsAt the back left you can see where the Blower has been mounted. It blows down into the box I built, and there is a 3" flex tube running to the shroud on each motor.
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PFC-50 location4630 viewsEven with the huge engine compartment that used to hold a 460cui engine, I'm having trouble cramming everything in.
A PFC-50 charger is BIG, and while there is lots of free space, none of it is the right shape for the charger, or there are other things that will be there.
So, it looks like I'll be mounting the charger at the back of the engine bay, behind the battery box, but tilted up so that I can still reach the controls on it.
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Ceramic Heater3527 viewsThis shows where it all mounts behind the glove box.
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Gauges5047 viewsI've mounted 4 gauges on the dash.
Charge Current, Pack Voltage, Battery Current, Motor Current.
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DC cabling5159 viewsThis shows the DC power cableing done - except for the battery boxes themselves.

Last additions - Ford F250 EV Conversion
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Decals on back3747 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 cabling5159 viewsThis shows the DC power cableing done - except for the battery boxes themselves.May 29, 2009
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Gauges5047 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 conduit3394 viewsThe conduit for the AC wiring under the truck.May 29, 2009
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Truck wiring conduit3751 viewsSome of the DC conduit runs under the truck.May 29, 2009
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Cables into bed5220 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 Boxes3536 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 truck5006 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