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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 2166 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 14410 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 1750 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 2323 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 2712 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 2301 times

Flywheel Mount


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Building the Flywheel Adapter

13 files, last one added on Feb 13, 2009
Album viewed 2644 times

Install Motors


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7 files, last one added on Apr 29, 2009
Album viewed 1714 times

Misc Items


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Miscellaneous parts installed

18 files, last one added on Apr 18, 2010
Album viewed 2698 times

Battery Boxes


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21 files, last one added on May 29, 2009
Album viewed 8345 times

Charging System


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15 files, last one added on May 29, 2009
Album viewed 4734 times

Heater


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3 files, last one added on May 15, 2009
Album viewed 1824 times

12 albums on 1 page(s)

Random files - Ford F250 EV Conversion
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Starting the 1st version of the Motor Coupler4617 viewsHere we are starting work on the first version of the coupler to connect the 2 Impulse 9" motors.
This is going to be a single piece coupler that press-fits on both shafts.
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Boring coupler shaft holes1999 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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Cooling it all off2706 viewsCooling the coupler down to keep the bearings from getting cooked.
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1st half coupler on motor2422 viewsMounted 1/2 the coupler on the first motor.
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Flywheel and cluth mounted3360 viewsBolted things together, bolted on the flywheel and clutch assemblies.
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Flywheel adapter boring shaft hole2382 viewsWe start the boring process using a big drill bit.
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Motor Shroud for Blower5047 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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Pack Voltage System Schematic5589 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)

Last additions - Ford F250 EV Conversion
DecalsOnBack.jpg
Decals on back4656 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 cabling6010 viewsThis shows the DC power cableing done - except for the battery boxes themselves.May 29, 2009
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Gauges5974 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 conduit4230 viewsThe conduit for the AC wiring under the truck.May 29, 2009
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Truck wiring conduit4578 viewsSome of the DC conduit runs under the truck.May 29, 2009
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Cables into bed6124 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 Boxes4136 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 truck5648 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