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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 1840 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 13719 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 1417 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 1759 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 2128 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 1733 times

Flywheel Mount


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Building the Flywheel Adapter

13 files, last one added on Feb 13, 2009
Album viewed 2073 times

Install Motors


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7 files, last one added on Apr 29, 2009
Album viewed 1389 times

Misc Items


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Miscellaneous parts installed

18 files, last one added on Apr 18, 2010
Album viewed 2139 times

Battery Boxes


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21 files, last one added on May 29, 2009
Album viewed 7675 times

Charging System


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15 files, last one added on May 29, 2009
Album viewed 4188 times

Heater


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3 files, last one added on May 15, 2009
Album viewed 1520 times

12 albums on 1 page(s)

Random files - Ford F250 EV Conversion
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Shortening the coupler1607 viewsWe did start with a piece of shaft that was too long, and decided it would be easier to cut off the excess with a saw, rather than cutting it all away with the lathe.
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Uncoupling the motors1784 viewsSo, we tried heating and prying to get the motors apart.
Nope, isn't going to work.
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Building Motor Mounting Framework7286 viewsWe decided it was easiest to juts build the motor mounting framework in place. Carefully cut pieces and clamp them in place, then tack weld it all together.
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2551 views
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7598 viewsThis shows how there will be 6 batteries across at the back. (there are 8 across at the front)
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Front Battery Box plywood3275 viewsThis is the box that sits in the Engine compartment. It will hold 6 GC batteries.
I still have to insulate and fiberglass it.
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AC Power Schematic2909 viewsThis is the schematic for the AC inlet power.
There are both 120V (standard 20A plug) and 240V (CS6375) AC power inlets.
Each has a separate breaker, and only 1 breaker can be ON at a time due to a mechanical interlock.
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Battery Box Mount2623 viewsThere are 2 5/8" bolts at the back of the box to hold the box down to the bed. To keep these from pulling through the wood/fiberglass box, I put a long 1/4" thick steel plate behind each bolt.

Last additions - Ford F250 EV Conversion
DecalsOnBack.jpg
Decals on back3720 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 cabling5135 viewsThis shows the DC power cableing done - except for the battery boxes themselves.May 29, 2009
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Gauges5020 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 conduit3370 viewsThe conduit for the AC wiring under the truck.May 29, 2009
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Truck wiring conduit3725 viewsSome of the DC conduit runs under the truck.May 29, 2009
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Cables into bed5194 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 Boxes3510 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 truck4980 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