Flywheel adapter - oops, hole too big2341 viewsWe didn't read the caliper quite correctly, and accidentally bored the mounting hole for the pilot bearing a bit too big. (20 thousandths or so)
So we brazed in some metal and had to re-do that hole.
Motor-Motor mount access holes2439 viewsIt was interesting putting the access holes in the mount.
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Motors Wired4246 viewsI wired the motors to the Z2K using 4/0 cable.
Notice that I don't like exposed High Voltage connections. Couldn't do much about the 1000A shunt though.
Charge Port Door switch5534 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.
Last additions - Ford F250 EV Conversion
Decals on back5148 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
DC cabling6499 viewsThis shows the DC power cableing done - except for the battery boxes themselves.May 29, 2009
Gauges6467 viewsI've mounted 4 gauges on the dash.
Charge Current, Pack Voltage, Battery Current, Motor Current.May 29, 2009
Truck wiring AC conduit4734 viewsThe conduit for the AC wiring under the truck.May 29, 2009
Truck wiring conduit5051 viewsSome of the DC conduit runs under the truck.May 29, 2009
Cables into bed6624 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
Breaker Boxes4620 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
Rear Battery box in truck6119 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