Pulling the engine11365 viewsRemoving the 460cui gas engine. (Having a forklift really made this easier.)
All 762 pounds of it!
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Position motors10472 viewsMotors were mounted to the transmission, then lifted in from below.
Transmission was then bolted to it's mounts, and the motors placed on blocks to keep everything in position
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Battery Box Bottom10110 viewsThis is the bottom of the battery box. It is 3/4" plywood with a 2x2 edge frame.
The colored boxes are pieces of plywood cut to the size of Golf Cart batteries.
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9585 viewsThis shows how there will be 6 batteries across at the back. (there are 8 across at the front)
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Building Motor Mounting Framework9518 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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Motors Installed8868 viewsEverything is in and bolted down. The framework is mounted to the original rubber engine mounts that used to support the 460cui Gas Engine.
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Painted Motor Mount7973 viewsI then sandblasted it all ,and painted it.
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Completed Motor Mount7778 viewsThis is the motor mounting framework, after all the welding was complete.
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Melted brake line7029 viewsThis shows the damage under the hood, after removing the charger and upper battery.
At the back of the 2 lower rear batteries, you can see 2 brake lines. One black, one white.
Guess which one melted...
At the back right, is where the melted line melted other tubes and wires.
Note that the brake line did NOT touch either of the rear battery posts!
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Cables into bed6629 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.
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DC cabling6505 viewsThis shows the DC power cableing done - except for the battery boxes themselves.
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Gauges6472 viewsI've mounted 4 gauges on the dash.
Charge Current, Pack Voltage, Battery Current, Motor Current.
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