PHEV Conversion #80ish

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.

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