CasaDelGato - Images from the House of the Cat

Home > Electric Vehicle > Ford F250 EV Conversion

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 1820 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 13668 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 1398 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 1729 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 2098 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 1701 times

Flywheel Mount


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Building the Flywheel Adapter

13 files, last one added on Feb 13, 2009
Album viewed 2043 times

Install Motors


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7 files, last one added on Apr 29, 2009
Album viewed 1370 times

Misc Items


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Miscellaneous parts installed

18 files, last one added on Apr 18, 2010
Album viewed 2112 times

Battery Boxes


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21 files, last one added on May 29, 2009
Album viewed 7625 times

Charging System


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15 files, last one added on May 29, 2009
Album viewed 4156 times

Heater


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3 files, last one added on May 15, 2009
Album viewed 1501 times

12 albums on 1 page(s)

Random files - Ford F250 EV Conversion
2009-01-02_20-17-50.JPG
Finishing the coupler1844 viewsHere we are putting the step in one end of the coupler so it can fit down into the end-bell of the motor.
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Flywheel adapter - finishing it up1886 viewsWe've cleaned up the pilot bearing hole, and are finishing the surface to the thickness needed.
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Adapter Plate alignment, contd 21598 viewsThen we mounted the Bell Housing adapter plate.
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Motor-Motor mount rough1776 viewsHere is the mount after some work in the lathe on both the raw pieces.
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Motor-Motor mount finished2392 viewsPainted all pretty
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Charge Port Door switch4542 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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Control Wiring2726 viewsThis is the main control wiring for the EV conversion. It has the Z2K Hairball, and all the various relays, meters, fuses, etc..
The 2 meters are AC Amps and Volts for the PFC-50 charger.
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Rear Battery box in truck4962 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.)

Last additions - Ford F250 EV Conversion
DecalsOnBack.jpg
Decals on back3702 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 cabling5115 viewsThis shows the DC power cableing done - except for the battery boxes themselves.May 29, 2009
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Gauges5000 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 conduit3351 viewsThe conduit for the AC wiring under the truck.May 29, 2009
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Truck wiring conduit3707 viewsSome of the DC conduit runs under the truck.May 29, 2009
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Cables into bed5175 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 Boxes3494 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
2009-05-18_17-44-44.JPG
Rear Battery box in truck4962 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