[david85]

I'm hoping for another week unless something else comes up. Still have to finish modifying the motor controller and mount it in the car, then I have to build/install the last battery box. Once the structural stuff is all installed, then I have to wire everything up (main cables, AND battery balancer harness).

Still waiting on some parts in the mail, but I hope to see them in another few days (vacuum brake stuff and DC/DC converter to run the 12V systems).

There will still be a ton of things left to do at that point, but the car can be driven under its own power even if just for a few miles. I'm certainly NOT going to miss pushing this car around!

[david85]

MOTOR CONTROLLER IS IN!!!!!!!!!!!

I had to trim down the cooling fins and make a different cover for the cooling fans, but it was worth it. The controller is nicely tucked under the hood (instead of having to put it in the trunk), and it looks ok too. I would guess there will be less than a quarter inch clearance between the controller and the hood when its done. I managed to trim over an inch off the package size. With some imagination it could be converted to liquid cooling and eliminate the cooling fins completely. For all I know that is optional from the manufacturer.

Right now its only resting on the transmission bell housing and has a support on the other side. Once I have the final battery box made, the controller will bolt into that instead of having redundant bracketry for the two assemblies.

[DIYguy]

Looking good David! Nice job on the cooling fan housing!

Gary

[david85]

Wait till ya see the final battery box! I am so gonna rip this car up and down the driveway as soon as I can (who needs power brakes anyway?)

[david85]

Final battery box 80% complete.

I threw in some close ups on the wields that I did. Anyone that is familiar with wielding sheet or auto body will recognize the method I am using. So far no warping. Its taken a while but I finally got the hang of wielding these boxes up. This is without a doubt the tightest box I built so far.

[david85]

Now for how it will fit in the car. There is about 1" of clearance to the hood, but I might decide to take much of that up to make sure the box doesn't knock against the motor underneath. Lid still has to be made, and there is a small piece missing but since I ran out of steam I dropped it in and took some shots then came in to warm up.

[electromet]

Nice and clean looking. Looks better than a factory job. Keep up the good work.

Mike

[Dave Koller]

Nice and clean work David ! I hope to get back on mine quick!

Keep it up ---

[david85]

Thanks guys.

Funny thing is I was just thinking about how this starting to look more like a factory conversion than a first timer's build. All I wanted was a clean setup when I started planning this. Maybe I went a little too far.

When its done, I'll probably take the hood off again and take a nice overhead view of the engine bay.
Looking at Frank Stronach's ford focus EV mule, they still took up space from the trunk.
http://images.google.ca/imgres?imgur...a%3DN%26um%3D1



Their battery is 23kwh, while mine is 30.7 (earlier 28.8 number I posted was incorrect) and I kept the cargo bay clear without ending up with a rear weight bias.

Magna claims the car will do 100 miles on 23kwh. Either they are being optimistic with range claims or my estimates are too low. I don't know the curb weight of the focus however.

EDIT: well it looks like I have an edge with curb weight as well. Focus is right around 3400lbs. Mine "should" be 3000.......

Hey Frank: can you fit snow boards AND luggage in your EV? cuzz I can! Mwuhahahahahahaah!!!!

Maybe I should hold off celebrating until I actually drive the darn thing
I think it will turn out good but you never know these things until they really happen.

[RKM]

David,

The aluminum looks so nice, you've got me wishing I'd have gone with Al as well! You've put alot of time and effort into the custom boxes and it shows.

"All I wanted was a clean setup when I started planning this. Maybe I went a little too far."

Like most of us, I don't think you'll ever regret doing a really nice job. From my experience, the regret comes from cutting corners or rushing things. A quality DIY conversion is a great ambassador for the EV cause. Keep on showing up Frank and the other "professionals".

Rob