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246 Build Your Own Electric VehicleShocks, coil and leaf springs, and external body parts are also best added at this timewhile you still have your heavy tools out.Cleanup from Mechanical to Electrical StageIt’s a good idea to use an air hose to clean up the engine compartment and rear pickupbox areas of your conversion after the mechanical phase is completed. Follow this witha broom sweep-up of the work area and/or a damp mop-up. The reason for this cleanupis to minimize the chance of metal strips or shavings finding their way into yourelectrical components or wiring during the electrical phase.ElectricalThe electrical part involves mounting the high-current, low-voltage, and chargercomponents and doing the electrical wiring to interconnect them. To do the electricalwiring requires knowledge of your EV’s grounding plan: the high-current system isfloating, the low-voltage system is grounded to the frame, and the charging system ACneutral is grounded to the frame when in use. Doing the electrical wiring also involvesknowledge of your EV’s safety plan: appropriate electrical interlocks must be providedin each system to assure system shutdown in the event of a malfunction, and to protectagainst accidental failure modes. The electrical wiring is also greatly facilitated by usinga junction box approach, so wiring is neat (no wires running every which way insidethe engine compartment) and you can later trace your wiring. Let’s take a closer look atthe steps.High-Current SystemFirst you attach the high-current components, then pull the AWG 2/0 cable to connectthem (another step where scheduling an inside helper is appropriate). Refer back toFigure 9-10. Notice there are seven components in the high-current line (in addition tobatteries and charger—these we’ll save for later):• Series DC motor• Motor controller• Circuit breaker• Main contactor• Safety fuse• Ammeter shunt(s)• Safety interlockYou’ve already mounted the motor. In Jim’s 1987 Ranger conversion, he mountedthe controller on an aluminum heat sink plate directly above the motor in the enginecompartment. Figure 10-17 shows the Operation Z layout of the batteries. Figure 10-18shows the passenger-side view of Jim’s series DC motor attached to the transmission(notice the earlier-mentioned torque arm between motor and frame), with its S1 powercable going up to the controller and motor, and controller power cables (with standoffclip to separate them) going down the chassis frame rail toward the rear battery pack.Figure 10-19 shows the layout of the electric motor in Paul Little’s car and how the
Chapter 10: Electric Vehicle Conversion 247Fi g u r e 10-17 Operation Z batter y mounted in place.Fi g u r e 10-18 Ford Ranger electric motor pow er cabling from the passenger’ s side.
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Build Your OwnElectric Vehicle
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Copyright © 2009 by The McGraw-Hil
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For more information about this tit
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ContentsviiRemember the 30 Percent
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Contentsix8 Batteries .............
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xiiContentsChargers ...............
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xviPrefaceFi g u r e 2 TH!NK City c
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xxAcknowledgmentscar conversions fo
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Chapter 1: Why Electric Vehicles Ar
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CHAPTER 2Electric VehiclesSave the
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Chapter 2: Electric Vehicles Save t
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CHAPTER 3Electric Vehicle History
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Page 222 and 223: 198Trojan Minutes Minutes Weight En
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298 Build Your Own Electric CarPaul
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310 Build Your Own Electric CarAsso
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314 IndexAssociation for Electric a
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316 Indexbuying an EV. See purchasi
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318 Indexcosts (continued)EV conver
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320 Indexelectrical system (continu
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322 IndexGGage, Tom, 69Galvani, Lui
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324 Indexlithium-ion batteries, 9,
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326 IndexPlymouth Arrow, 84pollutio
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328 IndexTaylor, Carl, 294Technolog
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