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


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.


Really Getting There

Posted in Assembly, Batteries, Design, Lights, Low Voltage System at 11:48 pm by Administrator

The battery boxes are complete. The Ah gauge has power, The lights work, I am finishing the bottom balancing of the pack. These are the latest pics.

More Wiring, Wiring, Soldering Wires, and Wiring

Posted in Accessories, Assembly, Batteries, Design, Lights, Low Voltage System at 12:12 am by Administrator

The light switch is installed and works properly. I was able to use the directional light switch I purchased in 2009 (and wasn’t able to use) which now functions as the turn switch and hi beam low beam switch. Ahh time and good ol book learnin are sure wonderful and useful tools. The directional lights, brake lights, headlights (Hi and low beam), and taillights are all hooked up and functioning properly.
The Batteries fit in the front in three rows of nine each just like little soldiers. I used two 3/4″ gland nuts to run the battery cables through the firewall. They will connect the front pack to the two rear packs. As I write this I am falling asleep so I think I better hit the hay.
Keep on Pluggin


Wiring, Correcting, and Porsche Seat Brackets

Posted in Accessories, Batteries, Heater, Lights, Low Voltage System, Seats at 5:55 pm by Administrator

Hello friends and neighbors, Today we will talk about the cost of errors both in materials and precious time. If you have been keeping up you remember I short changed one of the battery boxes. I am proud to say that this error has been corrected but it took a good hour or so to measure, cut, and glue together the new lexan box. Then Willie the Welder needed to modify his aluminum frames. We only need to add on 3″ to the existing structure. Sounds simple right? Simple if rebuilding half of the battery frame is “simple”. More time… tick tick tick… So what was productive? I figured out the headlight switch and wired the tail lights. I constructed GM style weatherproof connectors for the right and left taillights, headlights, directional lights, potentiometer, and the front and rear wire harness, I also hooked up the ignition switch so that it activates the fuse block. Lots of soldering. What is next? The Porsche 914 seats and brackets, the finishing up of the lighting system, Installing the batteries, Hooking up the DMOC to the DC to DC converter, a maintenance switch, adjust rear brakes, finish bottom balancing, charge and test. Oh I almost forgot… I need to redesign the dash panel. I am going to wait until the ReFuel event is over before I connect my heater. Probably wont need one anyway, its been very hot in California. Only two weeks left tick tick tick…


Memorial Weekend 2012

Posted in Batteries, Design, Lights, Low Voltage System, Seats at 6:11 pm by Administrator

Last Wed I finally got my seats. I put the passenger seat in the car and it fit almost perfectly. Fortunately I did not drill holes and bolt it in. When I tried to put the seat in the drivers side it did not fit and, will not fit without a major modification to the pan. I was downhearted. In addition, I noticed the shipping company must have set something heavy on the passenger seat. Further, there must have been something which leaked onto the seat and down to the cushion. More on that later. I decided to try fitting the seats out of the little grey Porsche 914 parts car into EV1E. THEY FIT PERFECTLY! They are light and there is only a small mod I have got to make to use them. I ordered the little seat mount brackets from Pelican Parts. Don’t know why I didn’t think of it before.
The bottom balancing continues. I have completed 11 batteries (only 31 to go.) On a “lighter” note…(pun intended) I went to The Ford dealership in Sonora and spoke with the repair guys in the repair and parts dept. They were extremely helpful in identifying all of the wiring in my light switch. One of the gentleman who sports the same name as me-self, even gave me a printout of the pin locations and a diagram of the headlight system. It seems lately everyone is interested in electric transportation and or knows somebody that is building, or converting or owns an electric vehicle. We’ve come a long way getting the word out since 2008 but still have a long way to go. The Ford guys were great and I promised to drive the car up to Sonora and show it to them when I am finished with the new mods. I want to test drive one of the new electric Focus’s. Next week I will be concentrating on the Battery boxes. EV1E is really coming together.
Until next time…
Keep On Pluggin


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


Deck Lid Latch

Posted in Aquisition, Lights, Low Voltage System, Teardown at 1:15 am by Administrator

On my way home from work I decided to stop by Little Dave’s place and see if I could salvage a switch off of the Bradley. I started to carefully remove the connectors from the switches only to discover that the switches fell apart. I gathered up all of the pieces and put them in my pocket. Then It occurred to me that The whole Instrument panel is held on by four screws. So I removed the instrument panel. I thought maybe I should get some connectors in case I needed them, instead I wound up carefully removing the entire wiring harness…and I didn’t have to cut one wire. Then I while I was under the back of the car removing the wiring harness I noticed the rear deck lid had the bracket and air cylinder I needed so I removed them as well. The rear deck lid stuff is now happily residing on EV1E and the panel is on my bench. The wiring harness is going in EV1E someday…maybe or maybe it will go in the Bradley it came from but for now it is out of the weather and safe in my shop.

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