Traction Pack Conduit

This is the installation of a 1 1/2" Liquidtight Flexible Conduit (Sealtite) to connect the front and rear portions of the traction pack through the passenger compartment. I used some Aluminum 2 1/2" chase nipples as bushings through a bulkhead and through the pan in the rear. Underneath the car the conduit runs around the right rear suspension pivot. I might add a mount down there so I can secure it to a fixed point and keep it from vibrating / rubbing. Otherwise I am pretty happy with how this came out. I feel this method offers excellent protection in the passenger compartment from the 120VDC cables. There will be two additional 1/2 Sealtite runs running along side of this larger run. One will carry 120 VAC tot he charger and the other will carry 120 VDC from the rear disconnect to the heater and DC/DC converter which are located up front.

Underbody Paint

Finally. I have been working towards this day for a very long time. I got the front (bonnet) done and the rear mostly painted. I need to go pick up some more paint. I have some time off of work this week so I'll be getting this finished on Wednesday I hope.

Front Junction Box

I've been working on this front junction box over the last week. It is about ready to put into the car. This box contains a heater contactor, fuses for the heater and for the DC/DC. Also it houses the main safety contactor which will break the main pack in case of a crash (inertia switch), or if the emergency "panic button" is pressed. Also in this box is a contactor which will keep the key switch disabled when 120VAC is present (charging). Lastly there is a current transformer which will allow measurement of overall current flow in the traction pack.

Getting ready for more sandblasting

I'm working on getting the rear areas ready for sandblasting. I'm also working on the safety/heat control junction box.

Another Productive Saturday

I've been working on this rear component board which I test fit into the car today. Everything fits so I'll continue putting this together in the basement at home. This "board" is a piece of PVC sheet with the charger, anderson connector and a j-box for the charger interlock contactor as well as the 120VDC feed to the front end of the car. That feed will power the heater core as well as the DC/DC converter.
I am also trying to wrap up the welding/metalwork on the front end by fixing the rotted out hood latch mounting area.
With Roy's help today we hooked up the installed warp-9 to a regular 12 volt battery as a bench test. It was amazing to see the wheels spin and the motor hum. After that I pulled the motor so I can sanblast the engine bay and paint it along with the front battery bay.

Sunday Car Day

I spent a whole day on the car on Sunday. Here are some pics.