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 2144 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 14332 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 1724 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 2275 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 2660 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 2253 times

Flywheel Mount


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Building the Flywheel Adapter

13 files, last one added on Feb 13, 2009
Album viewed 2592 times

Install Motors


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7 files, last one added on Apr 29, 2009
Album viewed 1692 times

Misc Items


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Miscellaneous parts installed

18 files, last one added on Apr 18, 2010
Album viewed 2647 times

Battery Boxes


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21 files, last one added on May 29, 2009
Album viewed 8275 times

Charging System


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15 files, last one added on May 29, 2009
Album viewed 4686 times

Heater


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3 files, last one added on May 15, 2009
Album viewed 1804 times

12 albums on 1 page(s)

Random files - Ford F250 EV Conversion
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Boring coupler shaft holes1991 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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Getting ready to put on the Flywheel adapter2392 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 work2284 viewsWe continue cutting
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Motor-Motor mount finished2792 viewsPainted all pretty
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Blower Mounted2538 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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12V System Power Schematic4848 viewsThis is the schematic for the 12V System only. (Blowers, pumps, etc...)
(Done with EagleCAD)
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Charge Port Door switch5220 viewsThis shows how I mounted a switch on each of the charge port doors. (used to be gas tank doors!)
This switch will tell the Z2K controller if either of the charge port doors is open, and if so, it won't let the truck "start".
Really helpful to prevent driving off with the cord still plugged in.
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Battery Hold Downs3392 viewsAll the battery hold down posts are in place. These are 3/8 allthread into the flange nuts on the bottom of the box.
There are posts on either side of each pair of batteries.
A square bar will be across the full width of the box, bolted to all the posts in that row.

Last additions - Ford F250 EV Conversion
DecalsOnBack.jpg
Decals on back4632 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 cabling5990 viewsThis shows the DC power cableing done - except for the battery boxes themselves.May 29, 2009
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Gauges5956 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 conduit4212 viewsThe conduit for the AC wiring under the truck.May 29, 2009
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Truck wiring conduit4563 viewsSome of the DC conduit runs under the truck.May 29, 2009
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Cables into bed6109 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 Boxes4122 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 truck5633 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