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Remove Gas Drive


Removing the Gas engine, fuel tanks, etc...

5 files, last one added on Feb 13, 2009
Album viewed 1943 times

Build Motor-Motor mount


Building the motor-motor mount to hold the 2 Impulse 9 motors together.

9 files, last one added on Feb 13, 2009
Album viewed 13903 times

Motor Coupler 1


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 1515 times

Assemble Motors 1


Assembling the motors together using version 1 of the motor-motor coupler.

9 files, last one added on Feb 13, 2009
Album viewed 1914 times

Motor Coupler 2


Our 2nd attempt at the motor-motor coupler.

6 files, last one added on Feb 13, 2009
Album viewed 2283 times

Assemble Motors 2


Assembling the motors using version 2 of the coupler

8 files, last one added on Feb 13, 2009
Album viewed 1883 times

Flywheel Mount


Building the Flywheel Adapter

13 files, last one added on Feb 13, 2009
Album viewed 2227 times

Install Motors


7 files, last one added on Apr 29, 2009
Album viewed 1492 times

Misc Items


Miscellaneous parts installed

18 files, last one added on Apr 18, 2010
Album viewed 2292 times

Battery Boxes


21 files, last one added on May 29, 2009
Album viewed 7864 times

Charging System


15 files, last one added on May 29, 2009
Album viewed 4327 times



3 files, last one added on May 15, 2009
Album viewed 1616 times

12 albums on 1 page(s)

Random files - Ford F250 EV Conversion
Bolting coupler together3203 viewsWe hadn't realized just how difficult it was going to be to tighten the bolts holding the coupler together. It was really awkward and hard. Took 2 people. (one turning the motor, the other holding the allen wrench.)
This was compouned when we discovered another alignment problem. Turns out that the end bells of the Impulse 9 motors aren't that accurately machine. We had a 10-20 thousandths variance between them that we had to shim.
Flywheel adapter work2055 viewsWe continue cutting
Flywheel adapter boring shaft hole2154 viewsWe start the boring process using a big drill bit.
Adapter Plate alignment, contd 21745 viewsThen we mounted the Bell Housing adapter plate.
2499 viewsShows were the 6 rows and 2 dividers will be.
Blower to cool the motors4094 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.
AC Power Schematic3066 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.
120V, 20A charge port3197 viewsAs you can see, it has the sideways prong to only allow a 20A rated cord to plug into it.
I'll carry an adapter for those times I need to plug into a 15A or less outlet.

Last additions - Ford F250 EV Conversion
Decals on back4112 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 cabling5516 viewsThis shows the DC power cableing done - except for the battery boxes themselves.May 29, 2009
Gauges5435 viewsI've mounted 4 gauges on the dash.
Charge Current, Pack Voltage, Battery Current, Motor Current.
May 29, 2009
Truck wiring AC conduit3726 viewsThe conduit for the AC wiring under the truck.May 29, 2009
Truck wiring conduit4090 viewsSome of the DC conduit runs under the truck.May 29, 2009
Cables into bed5609 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 Boxes3758 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 truck5266 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