06.30.12

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.

06.28.12

Long Week, 121 Gigawatts! what was thinking!

Posted in AC 24, Accessories, Assembly, Batteries, DMOC, High Voltage System, Low Voltage System, Relay Board, Road Test, Seats at 10:49 pm by Administrator

Ok here is the scoop. Today, The Day on the calendar wherein, in 1955 Marty McFly first went back to the future in Doc’s Delorean, EV1E received her first jolt of Lithium Power. A very historic day.
As I said it was a long week. I took Monday off thanks to the graciousness and understanding of my fabulous program manager. So what did I do with it? I finished wiring the Low Voltage system. I tested all the relays and made sure they all functioned properly. I re-read the instruction manual for my PL6 which is supposed to be able to discharge a battery at 40Amps. I went through all of the steps and the only thing I got was a message that said “Bad Cell Count” and no matter what I do that is all I can get. I called Revo and sent several emails but alas a good product is only as good as the support behind it. Given that rule I have to say that the PL6 is a bad product… only because of the lack of support, that and it wont do anything useful. Did I mention I called them… this started about three weeks ago and I have yet to hear from them.
That said and done I had to figure another way to balance my pack. This took some thought…
On Tuesday I hooked up the DC to DC converter and Willie the welder came over and we welded the new seat brackets in so that I could use the 914 seats… The seats were too high, 914 seats too high! We revisited the old bradley seats and made some modifications to them and that is what I am using. On Tuesday I we also put in the locking mechanism for the aft battery boxes. On Tues night I Started placing batteries in the boxes in the proper configuration. I also fitted the connecting cables which connect the front box to the aft boxes. Wed I spent most of the day trying to configure the PL6 to discharge more then 7.99Amps. Then Willie came over again and he took the seat brackets out so that the Old Bradley seats would fit. I also pulled the three point seatbelt system out of the Porsche 914 and installed it in EV1E. I used the roll bar for the harness attachment and the other two points are where I had the lap belt. Today was great! I decided I was going to hook up all of the main pack and check all the systems. They are working. I drove the car down the block and thought this car is sluggish… I drove back home and parked EV1E in the garage and went to apply the E Brake, it was already applied. I took off the E Brake and drove to the end of the block again this time with much more pep.
About balancing. I am going to charge the pack until the most charged battery reach’s 3.5 volts then, I am going to measure the lowest voltages and take the high voltage batts out of the string and charge everything up to 3.5Volts. Then reintroduce the charged batts which were removed and have a balanced pack. I can then run the car normally until the batteries are discharged to almost 2.75V then I can hand balance them. For Now I have just a little more to do and I am ready for Laguna Seca.

06.16.12

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…

05.25.12

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