Archive for January, 2008

PHEV Conversion #80? something continues…

Posted in PHEV on January 29, 2008 by wizbandit

The past few days were spent building the rear electronics and battery jumpers.  I decided to use two PVC J-Boxes to house the pair of HV contactors & control board.  The second J-Box will house the regen-diode, 60 amp DC fuse and a cooling fan operated by the control board.

Here is the first box.

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The second box is not complete yet, I still have to install the fuse holder and diode on its heat sink.

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Now, copper terminal lugs for #8 wire are not cheap.  I went to Home Depot Sunday to get 40 of them and decided a dollar each for copper bolt type was a bit too much.  The crimp version was even more expensive at over $1.50 each.  I opted to make my own.

I used #8 THHN stranded wire and 1/4″ soft copper tubing.  I cut the tubing into 3/4″ pieces and slide them onto the skinned ends of the wire after applying a liberal coat of rosin flux.  I then used vise-grips to flatten the tubing onto the wire.

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I then used a big soldering gun to flow solder into the crimp.

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I used a hand drill to drill a small 1/8″ pilot hole in the center of the new terminal. Next I clamped it in a drill vise and drilled it out to 3/16″ to fit the battery terminal bolt.

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The finished jumper after a bit of touch-up on the grinder and wire brush.

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These bolt up nice and cost a lot less.

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PHEV Conversion #80ish

Posted in PHEV on January 28, 2008 by wizbandit

This weekend was exciting, I started tearing into our 2008 PRIUS to convert it to a PHEV (Plug In Electric Vehicle)  I decided on using 18Ah SLA batteries from MK.  The MK ES17-12 cost me $37.50 when they came in even though I was quoted $34.50 when I ordered them.  Seems Battery prices are climbing daily.

The first step, using instructions from the http://www.CalCars.org open source project at http://www.eaa-phev.org/wiki/PriusPlus was to add the traction  battery tap.  This required a bit of dis-assembly including removing one rear seat.  This was done a few months ago in anticipation of the addition of the PHEV battery pack.

First, the battery tray bottom is constructed using 1 1/2″ x 1/8″ Aluminum angle with 3/8″ aluminum channel stock as battery separators.  I started out to get the angle at Home Depot but oh my gaud, $40 for a 8 foot piece!  I went next door to the local aluminum supply house and bought what I needed cut to length for $2.42 a foot.

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The ends are 3/4″ x 1/8″ aluminum angle.  This was chosen because these will be used to bolt the tray to the floor of the car.

I had to chisle some sound-junk off the floor to allow the frame to sit down on the floor.

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The frame was bolted to the floor using threaded 1/4-20″ pop-rivet inserts, four on each side.  I may install washers and nuts on the underside to insure they don’t pull out in a crash.

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I cut 1/4″ off one bracket to allow the frame to sit as far to the right as possible.

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After bolting the tray down the next step is hooking up the 20 batteries.  They are wired in series for a total nominal 260 Volts DC.  I still have some jumpers to make up, I ran out of steam and it was getting a bit chilly in the steel barn last night.

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The next step is to construct the HV control box and connect it to the computer mounted up on the dash.  I also need to construct the battery top that will bolt the batteries down and hold them in place.

FEDEX issued a Check…

Posted in Problems on January 10, 2008 by wizbandit

Finally I found out Fedex issued a check in the amount of $79.89 to ZIPZOOMFLY !!!  Now ZIPZOOMFLY has cashed the check and didn’t bother to contact me.  Now how screwed up is this?  My claim for for the $2.99 extra shipping for 2nd day and a 15% restocking fee from www.zipzoomfly.com  comes to just under $15 and Fedex pays THEM for the full amount of the laptop hard drive I ordered that Fedex sent back for no good reason!!!!  No phone numbers for ZIPZOOMFLY, only email.  I submitted a letter via their web site this morning to see if I can get my money.  Now only about $15 of the $79.89 is mine so now what do I do?  How much hassle is it going to be for me to get Fedex back the difference that is rightfully theirs?  I will persist untill all parties receive their due.

Check # 2678502 from Fedex was cashed by

ZIPZOOMFLY on 12-4-2007.

 10005073  SEAGATE ST9120822A 120GB PATA/IDE 5400 RPM 8MB HD $79.89
 
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  Sub Total:  $79.89 
  Discount:  $0.00 
  Sales Tax:  $0.00 
  Shipping:  $2.99 
 
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  ORDER TOTAL:  $82.88