[Ace_bridger]

Thanks Mike. I think I'll do that.

Originally Posted by skooler

got mine from here if that helps

http://www.ebay.co.uk/itm/Kilovac-EV...item43af8d50ee

They arrived quickly and had good customer service etc. If you buy them separately, on different days, they'll be shipped separately and you wont pay import tax

Cheers,

Mike

[Ace_bridger]

I tested the EV200 tonight by just connecting the wires straight to a 12V battery with no high voltage connected.

After 5-7 mins it was very hot on the base. I think I'll avoid using it and buy two more.

Also tonight, I removed the controller and associatted high and low voltage wiring (now that I know it all works). I have to glue in the thermocouple into the heatsink and apply some supportive non-corrosive silicon to the flying leads and to anything that looks like moving or vibrating.

...and made up a few of the battery interconnecting 35mm^2 cables.

[Ace_bridger]

I connected the rear pack tothe front pack today, connected up the controller, pre-charge contactor and throttle...all connected up to full 144V pack voltage. I only got a kick once when touching the pre-charge contactor even with no power there which surprised me!!

Well, despite not having the throttle actually connected to the throttle cable, she moves!!! I ran long wires from the controller to the throttle and had it in my hand in the cab and drove her from in there!!

Forwards and backwards she ran quite happily. In 1st, 2nd, 3rd and 4th she pulls away. 1st is fine but second is smoother.

No pics I'm afraid but this is a momentous day!! One step closer!!

Next step is to bolt the controller and contactors down, wire in the shut and ammeter and mount the volt meter.

Great fun. Pics to follow...oh, and brakes seem good with the new vacuum pump kit!!

[skooler]

You'll have EV grin for a few days now!

[Ace_bridger]

It's about time I posted some pictures as text is pretty dull.

I managed to secure my contactors and controller today. Also connected the in cab volt meter to monitor pack voltage at the controller.

Also built the throttle body sensor housing thing with sophisticated adjuster (2 long M6 bolts holding an old bit of aluminium - works well mind you).

I also managed a quick road test (on private roads as the car isn't road legal yet!! )

There are a few issues though. I wouldn't say the car is quiet, there's some mechanical noise when I pull away which is like something rubbing on the motor as it increases with motor rpm and road speed. The vacuum pump is also bloody noisey...it's only mounted on two of the four mounting bolts so some improvement hoped for when it's properly installed.

Brakes seem to work well though which was pleasing on the road test!!

I'm getting (what I assume to be) a high pedal lock-out sometimes when I first turn the car on but seeing as I'm a dumb-ass and didn't put the RS232 cable on the controller before fixing it in position I can't investigate fully. I'll take the controller out and put the lead on and re-assemble.

The day was spiced up by a few high voltage electric shocks which made things a little more fun!!

I think I'll ignore the mechanical noise for the time being and try and get the car road legal first and hope it goes away...if it doesn't I'll need to either investigate from beneath or remove everything from under the bonnet and investigate from there...I know I'm just putting of the inevitable but I have time pressures as I need the car road legal before the nights start drawing in...I normally cycle to work but don't want to cycle in the dark and wet.

Photos to follow...

PS. Bought a Subaru Impreza powered VW campoer last weekend!!!

[Ace_bridger]

This is the Rover 100 throttle body with TPS removed and motorsport hall effect sensor added. The aluminium I scrounged off a guy at work and the throttle body cost me 99p off eBay.

[Ace_bridger]

ANother shot of the throttle assembly with TPS in the foreground. That sensor is a prototype one but will be replaced by a pucker one once everything is assembled and proved. Cable adjuster can be seen on the right (the two M6 bolts).

Mounted on top of the controller. I will monitor whether or not the HE TPS signal is effected by the strong magnetic fields under the bonnet. Early indications are that it isn't.

[Ace_bridger]

That's the brake vacuum pump shown far right.

Originally Posted by Ace_bridger

ANother shot of the throttle assembly with TPS in the foreground. That sensor is a prototype one but will be replaced by a pucker one once everything is assembled and proved. Cable adjuster can be seen on the right (the two M6 bolts).

Mounted on top of the controller. I will monitor whether or not the HE TPS signal is effected by the strong magnetic fields under the bonnet. Early indications are that it isn't.

[Ace_bridger]

Pre-charge and main contactor with 100R 25w pre-charge resistor...needs tidying!!!!

[Ace_bridger]

She's alive!!! Big red button and cheap chinese voltmeter in the cab.

The voltmeter is showing battery voltage at the controller so that I can monitor the voltage when I turn the ignition on and ensure that pre-charge is happening. If I don't see decent volts within 7 secs on switching the ignition I can switch off and investigate.