Here I mounted the Curtis Controller on the panel above the cooling fan on top of the heat exchanger with a space for the air to flow. Electrical Panel Bottom View Almost Ready: Here you can see the cooling fan on the left and the Anderson Disconnect on the right. On top is the Curtis…
Saturday Big EV work day. Enjoyed it. I end up spending 15 hours with the goal of getting the EV drivable and test drive around the block. Finished the day and night not near the goal but I made steady progress never the less. Main goal was the electrical control panel. Here was the first…
The Electrical Control Board will hold as many electrical components as I can ‘jam on it’. Sounds like a hip-hop song. Started with 1/4″ thick smoked color Plexiglas 14″ X 22″ and I was given a piece of 1/4” electrical board fiberglass 13″ X 22″ to go under it. So I started with this now…
The weekend of the 8th was busy with a Royal Ambassador hiking trip to Nathan Bedford Forrest State Park. So come Monday I returned to the long term EV Saturn project. The 50 feet of 2/0 welding cable EVAmerica sent me, to do the conversion was not enough. BTW 2/0 is called “two aught”. I…
Finish making all the cables. Used the big 3 foot crimper and shrink wrap the ends. Here is a view of a pair of cables before assembly with the ends stripped, 4 automotive style lugs, 4 shrink-wraps, cable cutter, hose cutter, stripper, heat gun, cable end insulators (black and red) The two cables assembled Using…
The following three images are part of the process of making a battery box. Battery Frame test Fitting The decision on where to place the 6 remaining (of the 18 total needed) batteries that need to go under the hood has been a quandary. Some people like Micheal Drewry at http://glassphoto.googlepages.com/saturnev was able to place…
This weekend I install the motor and begin making the 2 mounts. The motor & transmission assembly had 4 mounts. Two of the four are regular rubber mounts and the other two are strut bars or torque bars. The top of the engine had a standard mount and the bottom under the oil pan had…
Motor & Adapter & hub The Adapter plate, hub and collar arrived from [[http://www.electroauto.com/|Electro Automotive]]. It took over 6-7 weeks but the parts look good. Nest, assembled the plate on the electric motor. It is important to adjust the hub, that bolts to and uses a wedge or taper-lock to fix a position on the…
The motor, controller and other major parts are arriving every day now. The batteries came in on the 23rd. sept 23 Batteries Arrived
I removed the instrument panel with gauges. Removed the lower drivers panel and upper full panel and drop the steering column. In the instrument panel I removed the fuel gauge and temperature sensor and replaced them with a high ammeter and high voltmeter. Had to do lots of trimming etc. Solder the back lighting for…