[monkmonkey]

Took it a spin and it appeared to perform flawlessly.No Sparking. Can someone list the parts I need to make it right?

[monkmonkey]

Where in the picture would the precharge resistor hookup?

[skooler]

Originally Posted by monkmonkey

Took it a spin and it appeared to perform flawlessly.No Sparking. Can someone list the parts I need to make it right?

Hi,

What kind of condition are the batteries in?

Do you have a budget?

I'd rip out the wiring and start again. It looks like an accident waiting to happen. Some of the crimps don't look great either. Buy some quality cable. 2/0 is a little overkill but a quality, thick (50mm2+) well insulated cable is a must.
Get some propper lugs, they're cheap as chips. Then buy or borrow a Crimper and make the cables. Ebay is a good source.

Keep your high voltage, high current cables closest to the base of the battery or terminal post. Don't separate with bolts, washers etc. Other cables can then be placed on top.

Sort out battery clamps to stop them from bouncing around. Check out my build thread for a cheap and simple way to clamp them down.

Add a precharge resistor as tesseract suggested

I'd be tempted to pull the motor and give it a good clean up.

Hope this helps,

Cheers

Mike

[major]

Originally Posted by monkmonkey

Where in the picture would the precharge resistor hookup?

Get the manual for your controller. If it is a Curtis, download it from the web site.

[monkmonkey]

According to the curtis manual, it says to connect resistor (light bulb) across the main contactor. I did that and it sparked. I'm confused How do I do this with a light bulb?

[major]

Originally Posted by monkmonkey

According to the curtis manual, it says to connect resistor (light bulb) across the main contactor. I did that and it sparked. I'm confused How do I do this with a light bulb?

Hi monk,

I'm all for helping a guy out, but it makes me feel better if you attempt to find the answers yourself. I cannot count the times I have seen questions about precharge on these forums over the years. Use the search feature in the header banner just above where you are reading this. Type in "precharge". It should bring back dozens of posts. I also think there is a section in the forum wiki about it. Take a few hours and read up on the subject....battery hold downs, wiring, precharge, etc. Look at examples in the garage and on the evalbum. Then come back and ask intelligent questions and be able to better understand comments and answers.

Just trying to help....really

major

[Tesseract]

Originally Posted by major

Wonder why he tapped 18 volts

I've learned not to ask such questions...

Oh, another thing I noticed - there is a splice in a high current cable (near top left battery) that is wrapped with plain old vinyl electrical tape instead of rubber splicing tape. It's probably also a safe bet that the splice wasn't done properly (looks like two ring lugs bolted together).

SandRailEV gave good advice: map out all of the connections and draw up a wiring diagram before doing anything else.