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 1801 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 13599 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 1382 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 1703 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 2071 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 1673 times

Flywheel Mount


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Building the Flywheel Adapter

13 files, last one added on Feb 13, 2009
Album viewed 2017 times

Install Motors


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7 files, last one added on Apr 29, 2009
Album viewed 1354 times

Misc Items


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Miscellaneous parts installed

18 files, last one added on Apr 18, 2010
Album viewed 2084 times

Battery Boxes


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21 files, last one added on May 29, 2009
Album viewed 7533 times

Charging System


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15 files, last one added on May 29, 2009
Album viewed 4126 times

Heater


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3 files, last one added on May 15, 2009
Album viewed 1479 times

12 albums on 1 page(s)

Random files - Ford F250 EV Conversion
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Starting the 2nd version of the Motor Coupler1864 viewsAfter our near-disaster with the 1st motor coupler, we decided to build the new one as a 2 piece unit. This will allow the motors to be separated if needed.
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Motor coupler work1674 viewsContinuing work on the coupler
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Examining the result1543 viewsHere we are looking at the result, and finding that the motors had NOT pressed far enough into the coupler.
We had a 1/2" of extra space to deal with.
We were going to just add a 1/2" spacer, until we did some measuring, and found that the motors were NOT coupled straight. There was a definite wobble.
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Uncoupling the motors1768 viewsSo, we tried heating and prying to get the motors apart.
Nope, isn't going to work.
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Adapter Plate alignment, contd 21592 viewsThen we mounted the Bell Housing adapter plate.
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Zilla Coolant Pump2619 viewsI bought a submersible pump for the Z2K cooling. I'm going to use the existing coolant reservoir from the truck as the tank.
I had to cut a hole in the top so I could insert the pump.
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120V, 20A charge port2914 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.
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Battery Box Bottom Insulation3178 viewsThe insulation on the bottom of the battery box is permanent, and will be encased in the fiberglass.
It's 2" (1.5" actual) foam board.

Last additions - Ford F250 EV Conversion
DecalsOnBack.jpg
Decals on back3694 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 cabling5105 viewsThis shows the DC power cableing done - except for the battery boxes themselves.May 29, 2009
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Gauges4991 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 conduit3342 viewsThe conduit for the AC wiring under the truck.May 29, 2009
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Truck wiring conduit3697 viewsSome of the DC conduit runs under the truck.May 29, 2009
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Cables into bed5164 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 Boxes3483 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 truck4949 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