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266 Build Your Own Electric VehicleEverytime Paul takes out his electric Porsche’s for a test, people cannot believe thereis no engine or sound in the acceleration. In the Palm Beach area of Florida, his car getsnoticed not just because it is a Porsche but because it is electric.Improved CoolingJim noticed after a few trial runs that he was getting an unusual thermal cutout indicationon the controller. Before finally isolating the culprit—it was a marginal controller thatFi g u r e 10-36 Jim Har ris’ redesigned “magic box” and controller mounting for 1987 Ford Ranger.
Chapter 10: Electric Vehicle Conversion 267Curtis quickly replaced under warranty—Jim did a thermal and mechanical redesignon the entire control electronics area.Figure 10-36 shows Jim’s “magic box” redesign. In this incarnation, everything isaccessible from the outside, the two power cables bolt on, the two instrumentationcables plug in, and the two fuses are accessible from outside the case. Figure 10-36shows a front view of the thermally redesigned controller mounting. In this design thecontroller is flipped over and a heat sink is mounted to its bottom (silicone thermallubricant was spread over the area for the highest heat dissipation efficiency). Thecombined package was then centrally mounted in the location of maximum enginecompartment airflow. Figure 10-37 shows a driver-side view: charger (in the originallocation), newly inverted controller with heat sink on top, and revision two of Jim’smagic box.When the replacement controller from Curtis was plugged into the new layout,everything worked fine with no more thermal cutout.Figure 11-38 shows the result.Further Improved CoolingThe eternal mechanic in Jim was still not satisfied—he wanted to have controller coolingindependent of the vagaries of engine compartment airflow. So he added the fan anddirectional cooling shroud to the top of the heat sink (Figure 10-38). He also widenedthe mounting space between his magic box and the controller (everything is nowmounted on the common heat sink aluminum plate), and relocated the battery chargerto the passenger side fender well—all to maximize cooling and airflow.Fi g u r e 10-37 “Magic box” and controller , driver-side vie w.
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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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126Vehicle gear 1st 1st 2nd 2nd 3rd
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198Trojan Minutes Minutes Weight En
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202Nominal Cell Operating Theoretic
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Page 338 and 339: 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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