Monday, July 27, 2009

Weld, Weld, Grind, Sweat

Whew! This metal working sure works up a sweat.
I have finished the motor mount and now I am installing some racks to mount the motor controller and a component board. The component board will have the charger, fuses, an Anderson disconnect, and a junction box for the heater relay and fuses and other misc. connections.
I moved on to the rear battery rack. I decided to go with 5 of the 10 batteries in the back (front) of the trunk. This will leave some space for groceries and stuff in the trunk. I had originally wanted to get the batteries down below the engine hatch but the controller is such a beast and there just wasn't room.
So I compromise, the batteries are a little high up, but they sit exactly over the rear suspension/ axles/ tires. And there is already a nice flat floor there.
The clearance to wire up the batteries is very tight,so in a few months I will be ranting and raving about what a bitch it is. I am going to get some big rubber gloves for insulation when I install the batteries.













Wednesday, July 22, 2009

Sunday, July 19, 2009

Motor is in...

At least temporarily. I need to make a motor support. I decided to start with the old motor mount. I removed the old motor support from the ICE and then made a plywood template and layed-out the location of the new motor. I bolted the template to the old motor support and cut out the circular shape with my cordless jigsaw. A little grinding cleaned up the high spots and it fit perfect.
Next I will get the welder set up and beef-up this bracket and provide mounting points to connect into the Warp9 Motor.