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2009-05-18_17-44-44.JPG
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.)
BlackTruck.JPG
Truck as purchased6020 viewsThis is the truck when I got it home. At this time, it does NOT have a transmission.
It weighs 5940 lbs. (It does have some amount of Gas, and a big toolbox)
First thing I did after getting it home was --- break the ignition switch. sigh. I had to drill it out and replace it.
TruckPackSystem.jpg
Pack Voltage System Schematic5867 viewsThis is the schematic for the Hi Voltage DC System.
It includes everything that connects to the pack.
I've left out a few of the hairball connections (like tach and tach sensor) that don't connect to anything else.
(Done with EagleCAD)
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Ceramic Heater5831 viewsThis is a 1500W Ceramic Heater mounted where the old Heater core was.
I kept the original overheat switch from the ceramic heater, and added another (at the top) just to be paranoid.
Since I'll be powering it from a 288V pack, I only need to use the center and outer connectors to the core.
2009-05-15_14-21-30.JPG
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.
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PFC-50 location5343 viewsEven with the huge engine compartment that used to hold a 460cui engine, I'm having trouble cramming everything in.
A PFC-50 charger is BIG, and while there is lots of free space, none of it is the right shape for the charger, or there are other things that will be there.
So, it looks like I'll be mounting the charger at the back of the engine bay, behind the battery box, but tilted up so that I can still reach the controls on it.
2009-03-19_13-31-44.JPG
Motor Shroud for Blower5331 viewsThis is the shroud I wrap around each motor (Brush end) to connect the ductwork from the blower.
It's made out of 4" wide aluminum flashing. Just cut with a carpet knife, and flex the cuts apart.
2009-04-08_09-31-40.JPG
Old Heater Core5192 viewsI was really surprised at how easy it was to get the old heater core out of the truck.
Just pop out the glovebox, and remove the panel behind it.
That uncovers the core.
DecalsOnBack.jpg
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.
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240V, 50A charge port5130 viewsThis is the 240V 50A charge port with a jack for a CS6364 plug.
Truck12VSystem.jpg
12V System Power Schematic5120 viewsThis is the schematic for the 12V System only. (Blowers, pumps, etc...)
(Done with EagleCAD)
2009-05-14_19-10-30.JPG
Motor wiring, Series5118 viewsAfter discussing things with several people, I decided to wire the motors in series.
This is because I have a fairly hi voltage page, and should be able to get enough RPM's even with the motors in series.
Also gives much better torque.
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