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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 1852 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 13751 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 1431 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 1779 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 2150 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 1754 times

Flywheel Mount


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Building the Flywheel Adapter

13 files, last one added on Feb 13, 2009
Album viewed 2091 times

Install Motors


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7 files, last one added on Apr 29, 2009
Album viewed 1406 times

Misc Items


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Miscellaneous parts installed

18 files, last one added on Apr 18, 2010
Album viewed 2159 times

Battery Boxes


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21 files, last one added on May 29, 2009
Album viewed 7710 times

Charging System


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15 files, last one added on May 29, 2009
Album viewed 4208 times

Heater


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3 files, last one added on May 15, 2009
Album viewed 1532 times

12 albums on 1 page(s)

Random files - Ford F250 EV Conversion
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Getting ready to put on the Flywheel adapter2020 viewsThe Flywheel adapter is also a heated press-fit. We made sure we had spacers to keep it from going on the shaft too far.
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Flywheel adapter - finishing it up1908 viewsWe've cleaned up the pilot bearing hole, and are finishing the surface to the thickness needed.
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Adapter Plate alignment finished2101 viewsThen we slid on the Motor adapter plate.
This allowed us to drill the holes to bolt the 2 plates together, and put in a couple of locating pins between them so they can be taken apart and re-assembled without shifting.
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Motors Installed6859 viewsEverything is in and bolted down. The framework is mounted to the original rubber engine mounts that used to support the 460cui Gas Engine.
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Motor Shroud for Blower4565 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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Blower to cool the motors3939 viewsThis is a 3 speed 12V blower I got from Surplus center.
I plan on having it come on in low speed whenever I turn the truck on, and it will switch to hi-speed if any of the motor thermostats trigger.
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Battery Hold Down Post Nuts2918 viewsI put a little weld in the bottom of each hold down flange nut so that the post can't be screwed in too far.
This is to prevent it being screwed down through the covering fiberglass at a later date.
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Battery Hold Down mounting3831 viewsBox is upside down. This shows all the flange nuts I put in the bottom for the battery hold downs to bolt into.

Last additions - Ford F250 EV Conversion
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Decals on back3735 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 cabling5149 viewsThis shows the DC power cableing done - except for the battery boxes themselves.May 29, 2009
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Gauges5036 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 conduit3387 viewsThe conduit for the AC wiring under the truck.May 29, 2009
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Truck wiring conduit3742 viewsSome of the DC conduit runs under the truck.May 29, 2009
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Cables into bed5211 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 Boxes3527 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 truck4997 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