Keep On Pluggin

Posted in Accessories, Gauges, Heater, Lights, Low Voltage System, Road Test, Tuning at 6:37 pm by Administrator

I received my GPS Speedometer from Speedhut. It sure is pretty. I am almost ready to embark on the long ride uphill from Delhi CA to Sonora CA. I only need to finish bottom balancing twenty more cells and then I can charge to a much higher capacity then I have been. In the meantime I am finishing the design of the interior and the process of sealing EVIE up for those colder wetter days. I also received my contactor for my heater which I designed last year. Lots to do and little time to do it. I just keep on pluggin away at it little by little. I am embarking on a new green business soon… watch this blog for further details… I can only say this… It involves Green devices, EV’s, Fairness, Public awareness, and Earthly preparedness. Thats all for now. I will let you know how the Central Valley to Foothills run goes.
If you have any questions or want to make a comment, feel free!
Keep On Pluggin


Mazda Laguna Seca Raceway, Monterey CA 07-01-2012

Posted in AC 24, Batteries, DMOC, Design, Drive Train, Gauges, High Voltage System, Lets All Plug In, Low Voltage System, Road Test, Tuning at 10:08 pm by Administrator

EV1E’s Debut as an LiFePo4 powered vehicle proved to be a success. We placed third in the “electric vehicle conversion” division (now ask me how many vehicles were in our division.) Not bad considering I have never driven on a race track. The event was wonderful and enlightening. There were more production cars then conversions. Representatives from Tesla, BMW, Coda, Nissan, as well as the Kleen Speed race team were present. This says something very positive about the future of electric vehicles and hopefully the future of our environment as well.


Yippee! We’re Ready to Go Dad!

Posted in AC 24, Assembly, Batteries, DMOC, Design, Drive Train, Gauges, High Voltage System, Lets All Plug In, Lights, Low Voltage System, Relay Board, Road Test, Seats, Sub Frame at 4:22 pm by Administrator

C'mon lets go!
These are my helpers. They were protesting that I couldn’t take them to Laguna Seca with me. This is an old fashioned “Sit In” They actually slept in the car last night and would not come in (the car was parked in the garage) the house.
We are ready for the big event at Laguna Seca tomorrow. Robert has volunteered his time and car trailer to the cause and we will be loading EV1E on the trailer eeearly in the morning. The Electric Automobile Association California Central Valley Chapter will be represented tomorrow!
I drove EV1E today and she “feels like a different car.” Jack Rickard of EVTV made this statement to me in one of our correspondences about the differences between lead and Lithium. He said when I change from lead to Lithium that my car will “feel like a different car” I wasn’t sure what he meant by it, I mean how could the same car feel completely different? Now I know what he meant EV1E feels more solid more responsive … tighter. Don’t know how else to explain it. Tomorrow is going to be a great way to see just what she can do.


OK Say’s Autopilot

Posted in AC 24, Accessories, Assembly, Batteries, DMOC, Design, Drive Train, Gauges, High Voltage System, Low Voltage System, Relay Board at 6:32 pm by Administrator

I have connected 4 batteries in parallel and am bottom balancing them all at the same time. Since I have to be away for a few days I thought I would Let the machines take over and when I called to check up on it I was told that they had already finished… I guess I will see soon enough, but if that is the case I will be able to do these much faster. Only a few days left and all I have to do is finish bottom balancing, hook up the main pack, hook up the DC to DC converter, weld in the seat brackets, seat belts and shoulder harnesses, adjust rear brakes, and hook up the instrumentation. Piece of cake! (gulp) Then I have to charge the pack and I will be ready to roll.


New Light Switch, JLD404 Multimeter

Posted in Gauges, Lights, Low Voltage System at 3:34 pm by Administrator

I found the perfect light switch. It is off of a 1996 mercury sable and as you can see will look very cool especially when the padding is in the dash. I also found a very accessible location for my JLD404 Ah meter. I have been bottom balancing batteries since my last post and have finished 6 of them. Only 36 to go. This weekend I am working but I brought some batteries to balance. I set up before I go to work then check on them when I get off work and if it is finished I start another one. The timing is about perfect. Each battery is numbered as it is set up.
Still haven’t received my seats. I am told they will be here soon… Of course I was told they should be here by the 17th, on the 17th. As Tom Petty says “The waiting is the hardest part”


A Combination of the Two

Posted in Design, Gauges, Lights, Low Voltage System at 2:22 am by Administrator

FIRST thing this morning, I installed the subframe. Eight nuts, twelve washers, Two U bolts, four huge bolts, one jack, two jack stands, three cups of coffee, and a lot of manipulation later, she hangs proudly below the pan with minimal damage to the paint.
I have made another decision based on the fact that the old wire harness just plain has too many unnecessary wires. I will be combining the EZ with the old style harness. I have left the middle harness in tact (the one that goes from the front to the back). I will probably find a use for some of the old engine ignition wires. Although the Bradley wire harness is original, I am carefully dissecting it and grafting it to the newer EZ harness. I have decided to use some more modern technology and research, for example: I am constructing weather proof connectors. They are much more professional looking and function much better then crimping.

Keep On Pluggin


Re Wire with Heat

Posted in Batteries, Bradley GT II Electrical Diagrams, Design, Gauges, Heater, Lights, Low Voltage System, Wipers at 4:36 pm by Administrator

Ok guys I finally got the heater installed properly and the plenum is in place. The wire harness is installed and anchored in several places. The wires are all labeled and I even found the schematic. I guess I didn’t give it away after all. So onward and upward. I ordered a harness weather kit and when It arrives I will make new connectors for the modified headlight and directional light system. Today I received my PowerLab 6 in the mail and will start bottom balancing my cells while I am working on the wiring. Today of course, I am at work so the balancing act will have to wait until later.

And so I plan… Three battery boxes built for easy access and durability as well as strength. Here is my plan. A lexan box with an aluminum frame riveted to the outside of it. The frame will be built from Aluminum L brackets. My neighbor Willie can weld aluminum so the brackets will be welded. With this setup you will be able to see the batteries and they will be protected. The design is light weight Aesthetically pleasing and durable (have you ever tried to break Lexan?)
I see three arrays of batteries. Two with eight cells each on either side of the motor and one big 26 cell module up front. the most pos and most neg terminals in the pack will be at the very back where they can be easily connected to the controller.
Then there is the speedometer, I have been looking at GPS speedometers and think I have found one suitable for my needs. I found it at the Speedhut
It is very cool and does not require anything additional to work. It comes with everything.
Next on the list is my interior… But that is another story
Keep On Pluggin


Interior Lighting -OR- Yes, Ground Wires are Filled with Smoke Too

Posted in Accessories, Gauges, Lights, Low Voltage System at 9:01 pm by Administrator

Today I set out to accomplish two main goals. The first goal is to set up a central ground terminal so I have ground within reach of my fiberglass dashboard. The second goal is to hook up the dash lights. Both goals were accomplished. The ground terminal I found is the same kind you would use for your house wiring. By installing this terminal I have already eliminated a number of wires. I hooked up the dash lights to the light switch and they work. This I am thrilled about because I have had to use my cell phone at night to see how fast I was going. While I was in wiring mode… I decided to hook up my last gauge, the volt meter which tells me the status of my 12 Volt accessory battery and my DC to DC converter. I found a wire coming from my fuse panel titled “Gauges” and used that for my hot lead. everything worked flawlessly until I attempted to tuck some wires to close the instrument panel. That is when the main headlight connector shook hands with the small ground wire I used for the tiny incandescent lights in the dash. The result as you might guess was all of the smoke that was previously contained in the little ground wire was released like a Genie out of a bottle the wire turned bright orange. There was no damage to the big headlight wire. I fixed the damaged ground wire, tested the system and all is bright for EV1E’s future.


Mission Accomplished! (for real)

Posted in AC 24, Batteries, DMOC, Drive Train, Gauges, High Voltage System, Lights, Low Voltage System, Relay Board, Road Test at 11:59 pm by Administrator

I drove my EV1E to work in daylight conditions and, back at night. A total of 56 miles, 26 of which was freeway driving. I didn’t push the pedal all the way to the floor but I still got 60mph on the freeway….A great day


Gauges and More Wires

Posted in Batteries, Design, Gauges, High Voltage System, Low Voltage System at 11:51 pm by Administrator

Key OFF Hi all! Today was spent trying to figure out why my ammeter wasn’t working properly. After consulting with the folks at Electro Automotive (Gary Snyder, Bill Lentfer) we determined that I may have the wrong type of shunt for my system. A shunt is a device which when hooked up to the main pack allows a small amount of voltage to be used for the “calibrated”gauge. This allows me to use small wires to the gauge instead of big battery cables. Since I have regenerative braking I have to have a shunt that allows current to flow in both directions. I am not real sure of the structure of the shunt but I think it runs by Thermal Dynamics, metallurgy and some kind of magic incantation. So once I realized that i was not going to fix that one today, I moved on.
My next task was to hook up the “State of Charge” gauge. This went flawlessly since, I already ran the wires when I made the loom which runs from my relay board to the front of the car. lastly I hooked up the DC/DC converter. This device acts like an alternator on a car, When the key is on it pulls juice uniformly from the main pack and uses it to charge the auxiliary 12V battery. After I got it all hooked up I put my volt meter leads on the aux batt and it read 12.42V, then I activated the DC/DC by turning on the key. When I measured this time it read 13.55V. This told me the DC/DC converter was charging the aux batt. The only pics I took today were of the State of Charge gauge.
Key ON