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70 Posts
Discussion Starter #1
And it was all going so well...

Got all charged up and went out to the hardware store, about 1.5 miles
away. It's on the highway, and the truck was really accelerating pretty
well right up to 60mph...when suddenly I heard a pop from behind me and
lost all my juice.

Darn.

I'm thinking (hoping) a fuse; there are two of them back there under the
bed. Thought I had everything wired up nice, and I was only giving it
about 100A, so I wonder why it would blow? Anyway, I didn't have any
props for the bed (doh!) so I had to walk back here and get some so I
can look and see. Now I'm headed back out there in my ICE car.

Anyhow, where do I get those huge fuses? Something tells me the hardware
store down the way isn't going to have them... I'll bet the electrical
supply joints are closed by now.

Thanks

Hunter

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Registered
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70 Posts
Discussion Starter #2
Hello Hunter,

Call directly to evparts.com and you will have them over nite or in a day.
Always carry spare parts in threes. When your fuse blows, you use one out
of the spares, leaving two. This leave you time to reorder for stock.

Some time we in our electrical work, will have a fuse blow because of aging
or not the correct type. You want the bolt in semi-conductor type which you
can get from EV Parts which they have in stock. Even my local electrical
supply store do not stock the correct size, so I have to have them order
them.

I carry a complete EV tool box, that has every replacement part I need to
repair or temporary fix the EV so I can move it. One time way back in the
stone age, I made a temporary fuse out of ganging together 50 to 100 amp
rated fuse wire and crimping all the ends together with a 2/0 wire terminal
to make a 400 amp fuse, while I waited for a replacement.

I also make up many jumper cables to jump out a bad battery and if I had to,
jump out the controller, and contactor drive it with 1/4 to 1/2 battery pack
voltage driving it very slowly in low gear.

Roland


----- Original Message -----
From: "Hunter Cook" <[email protected]>
To: "Electric Vehicle Discussion List" <[email protected]>
Sent: Thursday, November 01, 2007 4:34 PM
Subject: [EVDL] Arg!


> And it was all going so well...
>
> Got all charged up and went out to the hardware store, about 1.5 miles
> away. It's on the highway, and the truck was really accelerating pretty
> well right up to 60mph...when suddenly I heard a pop from behind me and
> lost all my juice.
>
> Darn.
>
> I'm thinking (hoping) a fuse; there are two of them back there under the
> bed. Thought I had everything wired up nice, and I was only giving it
> about 100A, so I wonder why it would blow? Anyway, I didn't have any
> props for the bed (doh!) so I had to walk back here and get some so I
> can look and see. Now I'm headed back out there in my ICE car.
>
> Anyhow, where do I get those huge fuses? Something tells me the hardware
> store down the way isn't going to have them... I'll bet the electrical
> supply joints are closed by now.
>
> Thanks
>
> Hunter
>
> _______________________________________________
> For subscription options, see
> http://lists.sjsu.edu/mailman/listinfo/ev
>

_______________________________________________
For subscription options, see
http://lists.sjsu.edu/mailman/listinfo/ev
 

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Registered
Joined
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70 Posts
Discussion Starter #3
Hunter, I don't know your rig, sorry, so will offer
the following guesses:
a) You have a low pack voltage, so compensate by
pulling lots of amps. Getting to freeway speed is a
sustained pull of amps, not a short one.
b) You are in a high gear for what you're trying to
do (say 3rd at 45 up a hill, instead of keeping in 2nd
with lower amps, higher RPMs). In my experience
though, this resulted in a battery terminal puddling,
not the fuse going... Hmmm.
c) You had a loose nut on the fuse where the problem
occurred in the first place.

That's all that comes to my mind...
Hope you figure out what the deal was.
peace,


--- Roland Wiench <[email protected]> wrote:

> Hello Hunter,
>
> Call directly to evparts.com and you will have them
> over nite or in a day.
> Always carry spare parts in threes. When your fuse
> blows, you use one out
> of the spares, leaving two. This leave you time to
> reorder for stock.
>
> Some time we in our electrical work, will have a
> fuse blow because of aging
> or not the correct type. You want the bolt in
> semi-conductor type which you
> can get from EV Parts which they have in stock.
> Even my local electrical
> supply store do not stock the correct size, so I
> have to have them order
> them.
>
> I carry a complete EV tool box, that has every
> replacement part I need to
> repair or temporary fix the EV so I can move it.
> One time way back in the
> stone age, I made a temporary fuse out of ganging
> together 50 to 100 amp
> rated fuse wire and crimping all the ends together
> with a 2/0 wire terminal
> to make a 400 amp fuse, while I waited for a
> replacement.
>
> I also make up many jumper cables to jump out a bad
> battery and if I had to,
> jump out the controller, and contactor drive it with
> 1/4 to 1/2 battery pack
> voltage driving it very slowly in low gear.
>
> Roland
>
>
> ----- Original Message -----
> From: "Hunter Cook" <[email protected]>
> To: "Electric Vehicle Discussion List"
> <[email protected]>
> Sent: Thursday, November 01, 2007 4:34 PM
> Subject: [EVDL] Arg!
>
>
> > And it was all going so well...
> >
> > Got all charged up and went out to the hardware
> store, about 1.5 miles
> > away. It's on the highway, and the truck was
> really accelerating pretty
> > well right up to 60mph...when suddenly I heard a
> pop from behind me and
> > lost all my juice.
> >
> > Darn.
> >
> > I'm thinking (hoping) a fuse; there are two of
> them back there under the
> > bed. Thought I had everything wired up nice, and I
> was only giving it
> > about 100A, so I wonder why it would blow? Anyway,
> I didn't have any
> > props for the bed (doh!) so I had to walk back
> here and get some so I
> > can look and see. Now I'm headed back out there in
> my ICE car.
> >
> > Anyhow, where do I get those huge fuses? Something
> tells me the hardware
> > store down the way isn't going to have them...
> I'll bet the electrical
> > supply joints are closed by now.
> >
> > Thanks
> >
> > Hunter
> >
> > _______________________________________________
> > For subscription options, see
> > http://lists.sjsu.edu/mailman/listinfo/ev
> >
>
> _______________________________________________
> For subscription options, see
> http://lists.sjsu.edu/mailman/listinfo/ev
>


Converting a gen. 5 Honda Civic? My $20 "CiviWithACord" DVD shows footage of my '92 sedan, as well as a del Sol and hatch too!
www.budget.net/~bbath/CivicWithACord.html
____
__/__|__\ __
=D-------/ - - \
'O'-----'O'-'
Would you still drive your car if the tailpipe came out of the steering wheel? Are you saving any gas for your kids?

__________________________________________________
Do You Yahoo!?
Tired of spam? Yahoo! Mail has the best spam protection around
http://mail.yahoo.com

_______________________________________________
For subscription options, see
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·
Registered
Joined
·
70 Posts
Discussion Starter #4
Bob-

You hit it on the head. Wasn't a fuse...once I got the bed up and the
cover off, I could see that one of the batteries had a melted post and a
cap blown off. As it happens I was at relatively low rpm in 4th gear,
although I was going downhill.

Anyway, while this was an expensive bit of stupidity, it was at least
easy to bypass the battery and drive home to lick my wounds.

Thanks for the post, now at least I know how I messed up.

Hunter

Bob Bath wrote:
> Hunter, I don't know your rig, sorry, so will offer
> the following guesses:
> a) You have a low pack voltage, so compensate by
> pulling lots of amps. Getting to freeway speed is a
> sustained pull of amps, not a short one.
> b) You are in a high gear for what you're trying to
> do (say 3rd at 45 up a hill, instead of keeping in 2nd
> with lower amps, higher RPMs). In my experience
> though, this resulted in a battery terminal puddling,
> not the fuse going... Hmmm.
> c) You had a loose nut on the fuse where the problem
> occurred in the first place.
>
> That's all that comes to my mind...
> Hope you figure out what the deal was.
> peace,
>
>
> --- Roland Wiench <[email protected]> wrote:
>
> > Hello Hunter,
> >
> > Call directly to evparts.com and you will have them
> > over nite or in a day.
> > Always carry spare parts in threes. When your fuse
> > blows, you use one out
> > of the spares, leaving two. This leave you time to
> > reorder for stock.
> >
> > Some time we in our electrical work, will have a
> > fuse blow because of aging
> > or not the correct type. You want the bolt in
> > semi-conductor type which you
> > can get from EV Parts which they have in stock.
> > Even my local electrical
> > supply store do not stock the correct size, so I
> > have to have them order
> > them.
> >
> > I carry a complete EV tool box, that has every
> > replacement part I need to
> > repair or temporary fix the EV so I can move it.
> > One time way back in the
> > stone age, I made a temporary fuse out of ganging
> > together 50 to 100 amp
> > rated fuse wire and crimping all the ends together
> > with a 2/0 wire terminal
> > to make a 400 amp fuse, while I waited for a
> > replacement.
> >
> > I also make up many jumper cables to jump out a bad
> > battery and if I had to,
> > jump out the controller, and contactor drive it with
> > 1/4 to 1/2 battery pack
> > voltage driving it very slowly in low gear.
> >
> > Roland
> >
> >
> > ----- Original Message -----
> > From: "Hunter Cook" <[email protected]>
> > To: "Electric Vehicle Discussion List"
> > <[email protected]>
> > Sent: Thursday, November 01, 2007 4:34 PM
> > Subject: [EVDL] Arg!
> >
> >
> > > And it was all going so well...
> > >
> > > Got all charged up and went out to the hardware
> > store, about 1.5 miles
> > > away. It's on the highway, and the truck was
> > really accelerating pretty
> > > well right up to 60mph...when suddenly I heard a
> > pop from behind me and
> > > lost all my juice.
> > >
> > > Darn.
> > >
> > > I'm thinking (hoping) a fuse; there are two of
> > them back there under the
> > > bed. Thought I had everything wired up nice, and I
> > was only giving it
> > > about 100A, so I wonder why it would blow? Anyway,
> > I didn't have any
> > > props for the bed (doh!) so I had to walk back
> > here and get some so I
> > > can look and see. Now I'm headed back out there in
> > my ICE car.
> > >
> > > Anyhow, where do I get those huge fuses? Something
> > tells me the hardware
> > > store down the way isn't going to have them...
> > I'll bet the electrical
> > > supply joints are closed by now.
> > >
> > > Thanks
> > >
> > > Hunter
> > >
> > > _______________________________________________
> > > For subscription options, see
> > > http://lists.sjsu.edu/mailman/listinfo/ev
> > >
> >
> > _______________________________________________
> > For subscription options, see
> > http://lists.sjsu.edu/mailman/listinfo/ev
> >
>
>
> Converting a gen. 5 Honda Civic? My $20 "CiviWithACord" DVD shows footage of my '92 sedan, as well as a del Sol and hatch too!
> www.budget.net/~bbath/CivicWithACord.html
> ____
> __/__|__\ __
> =D-------/ - - \
> 'O'-----'O'-'
> Would you still drive your car if the tailpipe came out of the steering wheel? Are you saving any gas for your kids?
>
> __________________________________________________
> Do You Yahoo!?
> Tired of spam? Yahoo! Mail has the best spam protection around
> http://mail.yahoo.com
>
> _______________________________________________
> For subscription options, see
> http://lists.sjsu.edu/mailman/listinfo/ev

_______________________________________________
For subscription options, see
http://lists.sjsu.edu/mailman/listinfo/ev
 

·
Registered
Joined
·
70 Posts
Discussion Starter #5
So, by the way...can I replace the post on this battery? Is it likely to
have other problems? Surely it's not just toast at this point, is it?

Thanks

Hunter

Hunter Cook wrote:
> Bob-
>
> You hit it on the head. Wasn't a fuse...once I got the bed up and the
> cover off, I could see that one of the batteries had a melted post and a
> cap blown off. As it happens I was at relatively low rpm in 4th gear,
> although I was going downhill.
>
> Anyway, while this was an expensive bit of stupidity, it was at least
> easy to bypass the battery and drive home to lick my wounds.
>
> Thanks for the post, now at least I know how I messed up.
>
> Hunter
>
> On Thu, 2007-11-01 at 17:23 -0700, Bob Bath wrote:
> > Hunter, I don't know your rig, sorry, so will offer
> > the following guesses:
> > a) You have a low pack voltage, so compensate by
> > pulling lots of amps. Getting to freeway speed is a
> > sustained pull of amps, not a short one.
> > b) You are in a high gear for what you're trying to
> > do (say 3rd at 45 up a hill, instead of keeping in 2nd
> > with lower amps, higher RPMs). In my experience
> > though, this resulted in a battery terminal puddling,
> > not the fuse going... Hmmm.
> > c) You had a loose nut on the fuse where the problem
> > occurred in the first place.
> >
> > That's all that comes to my mind...
> > Hope you figure out what the deal was.
> > peace,
> >
> >
> > --- Roland Wiench <[email protected]> wrote:
> >
> > > Hello Hunter,
> > >
> > > Call directly to evparts.com and you will have them
> > > over nite or in a day.
> > > Always carry spare parts in threes. When your fuse
> > > blows, you use one out
> > > of the spares, leaving two. This leave you time to
> > > reorder for stock.
> > >
> > > Some time we in our electrical work, will have a
> > > fuse blow because of aging
> > > or not the correct type. You want the bolt in
> > > semi-conductor type which you
> > > can get from EV Parts which they have in stock.
> > > Even my local electrical
> > > supply store do not stock the correct size, so I
> > > have to have them order
> > > them.
> > >
> > > I carry a complete EV tool box, that has every
> > > replacement part I need to
> > > repair or temporary fix the EV so I can move it.
> > > One time way back in the
> > > stone age, I made a temporary fuse out of ganging
> > > together 50 to 100 amp
> > > rated fuse wire and crimping all the ends together
> > > with a 2/0 wire terminal
> > > to make a 400 amp fuse, while I waited for a
> > > replacement.
> > >
> > > I also make up many jumper cables to jump out a bad
> > > battery and if I had to,
> > > jump out the controller, and contactor drive it with
> > > 1/4 to 1/2 battery pack
> > > voltage driving it very slowly in low gear.
> > >
> > > Roland
> > >
> > >
> > > ----- Original Message -----
> > > From: "Hunter Cook" <[email protected]>
> > > To: "Electric Vehicle Discussion List"
> > > <[email protected]>
> > > Sent: Thursday, November 01, 2007 4:34 PM
> > > Subject: [EVDL] Arg!
> > >
> > >
> > > > And it was all going so well...
> > > >
> > > > Got all charged up and went out to the hardware
> > > store, about 1.5 miles
> > > > away. It's on the highway, and the truck was
> > > really accelerating pretty
> > > > well right up to 60mph...when suddenly I heard a
> > > pop from behind me and
> > > > lost all my juice.
> > > >
> > > > Darn.
> > > >
> > > > I'm thinking (hoping) a fuse; there are two of
> > > them back there under the
> > > > bed. Thought I had everything wired up nice, and I
> > > was only giving it
> > > > about 100A, so I wonder why it would blow? Anyway,
> > > I didn't have any
> > > > props for the bed (doh!) so I had to walk back
> > > here and get some so I
> > > > can look and see. Now I'm headed back out there in
> > > my ICE car.
> > > >
> > > > Anyhow, where do I get those huge fuses? Something
> > > tells me the hardware
> > > > store down the way isn't going to have them...
> > > I'll bet the electrical
> > > > supply joints are closed by now.
> > > >
> > > > Thanks
> > > >
> > > > Hunter
> > > >
> > > > _______________________________________________
> > > > For subscription options, see
> > > > http://lists.sjsu.edu/mailman/listinfo/ev
> > > >
> > >
> > > _______________________________________________
> > > For subscription options, see
> > > http://lists.sjsu.edu/mailman/listinfo/ev
> > >
> >
> >
> > Converting a gen. 5 Honda Civic? My $20 "CiviWithACord" DVD shows footage of my '92 sedan, as well as a del Sol and hatch too!
> > www.budget.net/~bbath/CivicWithACord.html
> > ____
> > __/__|__\ __
> > =D-------/ - - \
> > 'O'-----'O'-'
> > Would you still drive your car if the tailpipe came out of the steering wheel? Are you saving any gas for your kids?
> >
> > __________________________________________________
> > Do You Yahoo!?
> > Tired of spam? Yahoo! Mail has the best spam protection around
> > http://mail.yahoo.com
> >
> > _______________________________________________
> > For subscription options, see
> > http://lists.sjsu.edu/mailman/listinfo/ev
>
> _______________________________________________
> For subscription options, see
> http://lists.sjsu.edu/mailman/listinfo/ev

_______________________________________________
For subscription options, see
http://lists.sjsu.edu/mailman/listinfo/ev
 

·
Registered
Joined
·
70 Posts
Discussion Starter #6
Hello Hunter,

You can add a temporary post to this battery. I did this several times
right in the EV, so I can melt in a new post with the battery remove latter
on.

1st go to a auto parts store, and get one of those post that screws can
screw into a side mount post of a battery. These may have a 5/16 or 3/8 bolt
stud coming out of it. I like to use the one that has a hex base on it, so
you can use a box wrench on it.

Next, you must level the top of the post, so I drill a small pilot hole with
a 1/8 inch drill bit with a round stop on the drill so you do not drill too
deep or through the top of the plastic case if you battery post is setting
on a offset link.

Then use a 1 inch wide wood speed bit. This bit has a flat surface, so it
will level the post surface.

Next, drill a larger pilot hole into the 1/8 inch hole you drill in the top
of the post. If you screw in post has a 5/16 inch stud in it, than drill
this pilot hole with a 1/4 inch drill with a stop on it. If it's a 3/8
stud, then drill a 5/15 inch pilot hole.

Use a tap set with the threads to match the post stud. The tap set is
normally three taps, that will be a taper, plug, and bottom tap. You first
start with the taper tap and work it back and forth, to clear the metal
shavings. Do not screw it in like a wood screw but you must press it in
hard, so it does not skip back and strip the threads.

After you went in as far as you can with the taper tap, then tap again with
the plug and then tap with the bottom tap.

Before you screw the post into this tap hole, take one of those stainless
steel wire brushes and rough up the bottom of the screw in post, so as to
brighten it up.

Screw in this post and tighten it to 100 inch lbs which is the same as 8.3
foot lbs.

This is a temporary post fix. It may last to your next battery replacement,
or you can remove it and melt in a new post, which requires post molds, pure
lead sticks, a mini torch that has a long thin hot flame and lot of practice
on old batteries to get it right.

Some battery dealers can repair batteries and install a new post for you or
you get these battery repair tools and supplies from them.

Roland






----- Original Message -----
From: "Hunter Cook" <[email protected]>
To: "Electric Vehicle Discussion List" <[email protected]>
Sent: Thursday, November 01, 2007 8:30 PM
Subject: Re: [EVDL] Arg!


> So, by the way...can I replace the post on this battery? Is it likely to
> have other problems? Surely it's not just toast at this point, is it?
>
> Thanks
>
> Hunter
>
>
Hunter Cook wrote:
> > Bob-
> >
> > You hit it on the head. Wasn't a fuse...once I got the bed up and the
> > cover off, I could see that one of the batteries had a melted post and a
> > cap blown off. As it happens I was at relatively low rpm in 4th gear,
> > although I was going downhill.
> >
> > Anyway, while this was an expensive bit of stupidity, it was at least
> > easy to bypass the battery and drive home to lick my wounds.
> >
> > Thanks for the post, now at least I know how I messed up.
> >
> > Hunter
> >
> > On Thu, 2007-11-01 at 17:23 -0700, Bob Bath wrote:
> > > Hunter, I don't know your rig, sorry, so will offer
> > > the following guesses:
> > > a) You have a low pack voltage, so compensate by
> > > pulling lots of amps. Getting to freeway speed is a
> > > sustained pull of amps, not a short one.
> > > b) You are in a high gear for what you're trying to
> > > do (say 3rd at 45 up a hill, instead of keeping in 2nd
> > > with lower amps, higher RPMs). In my experience
> > > though, this resulted in a battery terminal puddling,
> > > not the fuse going... Hmmm.
> > > c) You had a loose nut on the fuse where the problem
> > > occurred in the first place.
> > >
> > > That's all that comes to my mind...
> > > Hope you figure out what the deal was.
> > > peace,
> > >
> > >
> > > --- Roland Wiench <[email protected]> wrote:
> > >
> > > > Hello Hunter,
> > > >
> > > > Call directly to evparts.com and you will have them
> > > > over nite or in a day.
> > > > Always carry spare parts in threes. When your fuse
> > > > blows, you use one out
> > > > of the spares, leaving two. This leave you time to
> > > > reorder for stock.
> > > >
> > > > Some time we in our electrical work, will have a
> > > > fuse blow because of aging
> > > > or not the correct type. You want the bolt in
> > > > semi-conductor type which you
> > > > can get from EV Parts which they have in stock.
> > > > Even my local electrical
> > > > supply store do not stock the correct size, so I
> > > > have to have them order
> > > > them.
> > > >
> > > > I carry a complete EV tool box, that has every
> > > > replacement part I need to
> > > > repair or temporary fix the EV so I can move it.
> > > > One time way back in the
> > > > stone age, I made a temporary fuse out of ganging
> > > > together 50 to 100 amp
> > > > rated fuse wire and crimping all the ends together
> > > > with a 2/0 wire terminal
> > > > to make a 400 amp fuse, while I waited for a
> > > > replacement.
> > > >
> > > > I also make up many jumper cables to jump out a bad
> > > > battery and if I had to,
> > > > jump out the controller, and contactor drive it with
> > > > 1/4 to 1/2 battery pack
> > > > voltage driving it very slowly in low gear.
> > > >
> > > > Roland
> > > >
> > > >
> > > > ----- Original Message -----
> > > > From: "Hunter Cook" <[email protected]>
> > > > To: "Electric Vehicle Discussion List"
> > > > <[email protected]>
> > > > Sent: Thursday, November 01, 2007 4:34 PM
> > > > Subject: [EVDL] Arg!
> > > >
> > > >
> > > > > And it was all going so well...
> > > > >
> > > > > Got all charged up and went out to the hardware
> > > > store, about 1.5 miles
> > > > > away. It's on the highway, and the truck was
> > > > really accelerating pretty
> > > > > well right up to 60mph...when suddenly I heard a
> > > > pop from behind me and
> > > > > lost all my juice.
> > > > >
> > > > > Darn.
> > > > >
> > > > > I'm thinking (hoping) a fuse; there are two of
> > > > them back there under the
> > > > > bed. Thought I had everything wired up nice, and I
> > > > was only giving it
> > > > > about 100A, so I wonder why it would blow? Anyway,
> > > > I didn't have any
> > > > > props for the bed (doh!) so I had to walk back
> > > > here and get some so I
> > > > > can look and see. Now I'm headed back out there in
> > > > my ICE car.
> > > > >
> > > > > Anyhow, where do I get those huge fuses? Something
> > > > tells me the hardware
> > > > > store down the way isn't going to have them...
> > > > I'll bet the electrical
> > > > > supply joints are closed by now.
> > > > >
> > > > > Thanks
> > > > >
> > > > > Hunter
> > > > >
> > > > > _______________________________________________
> > > > > For subscription options, see
> > > > > http://lists.sjsu.edu/mailman/listinfo/ev
> > > > >
> > > >
> > > > _______________________________________________
> > > > For subscription options, see
> > > > http://lists.sjsu.edu/mailman/listinfo/ev
> > > >
> > >
> > >
> > > Converting a gen. 5 Honda Civic? My $20 "CiviWithACord" DVD shows
> > > footage of my '92 sedan, as well as a del Sol and hatch too!
> > > www.budget.net/~bbath/CivicWithACord.html
> > > ____
> > > __/__|__\ __
> > > =D-------/ - - \
> > > 'O'-----'O'-'
> > > Would you still drive your car if the tailpipe came out of the
> > > steering wheel? Are you saving any gas for your kids?
> > >
> > > __________________________________________________
> > > Do You Yahoo!?
> > > Tired of spam? Yahoo! Mail has the best spam protection around
> > > http://mail.yahoo.com
> > >
> > > _______________________________________________
> > > For subscription options, see
> > > http://lists.sjsu.edu/mailman/listinfo/ev
> >
> > _______________________________________________
> > For subscription options, see
> > http://lists.sjsu.edu/mailman/listinfo/ev
>
> _______________________________________________
> For subscription options, see
> http://lists.sjsu.edu/mailman/listinfo/ev
>

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Registered
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70 Posts
Discussion Starter #7
Hunter,

You sound like you have a similar experience that I had a few weeks ago, in
my little 74 VW beetle. I had taken it on several small journeys around my
neighborhood. Then I decided to see if it would do the trip to school,
which is 14 miles away. I decided that I would go about half way, and then
return. Well, my car at around 55 mph, has a shake in the front end. I
tried to avoid this, when I remembered. (It has been a little while since I
have driven it at that speed.) But the damage had been done, and on the
return part, I was trying to go up hill, and almost at the top, no power. I
went to check the front batteries, I noticed a post was gone. The shake I
think loosened one of the nuts, which made the connection loose, which
caused extra resistance, which melted a post. I called a neighbor who towed
me home, with "my tail between my legs."

So now I am rethinking the abilities of the car. I haven't been able to get
the front end shake fixed. I have been to two shops, which have been known
for VW repair, and it never stays fixed. So I think I will be selling my
curtis 1231C, dropping down to 84V, buy a Kelly Controller rated at 200 or
300 amps, and make it my NEV. A very disappointing turn for the worse.

So I will change the subject a little. Anyone who would like to have a
Curtis 1231, rated for 96 - 144 V, and 500 amps, contact me off-list. Also,
I would like to hear what people have to say about the Kelly Controllers.
Are they working fine?

Good luck, Hunter.

Brian

On 11/1/07, Hunter Cook <[email protected]> wrote:
>
> Bob-
>
> You hit it on the head. Wasn't a fuse...once I got the bed up and the
> cover off, I could see that one of the batteries had a melted post and a
> cap blown off. As it happens I was at relatively low rpm in 4th gear,
> although I was going downhill.
>
> Anyway, while this was an expensive bit of stupidity, it was at least
> easy to bypass the battery and drive home to lick my wounds.
>
> Thanks for the post, now at least I know how I messed up.
>
> Hunter
>
>
Bob Bath wrote:
> > Hunter, I don't know your rig, sorry, so will offer
> > the following guesses:
> > a) You have a low pack voltage, so compensate by
> > pulling lots of amps. Getting to freeway speed is a
> > sustained pull of amps, not a short one.
> > b) You are in a high gear for what you're trying to
> > do (say 3rd at 45 up a hill, instead of keeping in 2nd
> > with lower amps, higher RPMs). In my experience
> > though, this resulted in a battery terminal puddling,
> > not the fuse going... Hmmm.
> > c) You had a loose nut on the fuse where the problem
> > occurred in the first place.
> >
> > That's all that comes to my mind...
> > Hope you figure out what the deal was.
> > peace,
> >
> >
> > --- Roland Wiench <[email protected]> wrote:
> >
> > > Hello Hunter,
> > >
> > > Call directly to evparts.com and you will have them
> > > over nite or in a day.
> > > Always carry spare parts in threes. When your fuse
> > > blows, you use one out
> > > of the spares, leaving two. This leave you time to
> > > reorder for stock.
> > >
> > > Some time we in our electrical work, will have a
> > > fuse blow because of aging
> > > or not the correct type. You want the bolt in
> > > semi-conductor type which you
> > > can get from EV Parts which they have in stock.
> > > Even my local electrical
> > > supply store do not stock the correct size, so I
> > > have to have them order
> > > them.
> > >
> > > I carry a complete EV tool box, that has every
> > > replacement part I need to
> > > repair or temporary fix the EV so I can move it.
> > > One time way back in the
> > > stone age, I made a temporary fuse out of ganging
> > > together 50 to 100 amp
> > > rated fuse wire and crimping all the ends together
> > > with a 2/0 wire terminal
> > > to make a 400 amp fuse, while I waited for a
> > > replacement.
> > >
> > > I also make up many jumper cables to jump out a bad
> > > battery and if I had to,
> > > jump out the controller, and contactor drive it with
> > > 1/4 to 1/2 battery pack
> > > voltage driving it very slowly in low gear.
> > >
> > > Roland
> > >
> > >
> > > ----- Original Message -----
> > > From: "Hunter Cook" <[email protected]>
> > > To: "Electric Vehicle Discussion List"
> > > <[email protected]>
> > > Sent: Thursday, November 01, 2007 4:34 PM
> > > Subject: [EVDL] Arg!
> > >
> > >
> > > > And it was all going so well...
> > > >
> > > > Got all charged up and went out to the hardware
> > > store, about 1.5 miles
> > > > away. It's on the highway, and the truck was
> > > really accelerating pretty
> > > > well right up to 60mph...when suddenly I heard a
> > > pop from behind me and
> > > > lost all my juice.
> > > >
> > > > Darn.
> > > >
> > > > I'm thinking (hoping) a fuse; there are two of
> > > them back there under the
> > > > bed. Thought I had everything wired up nice, and I
> > > was only giving it
> > > > about 100A, so I wonder why it would blow? Anyway,
> > > I didn't have any
> > > > props for the bed (doh!) so I had to walk back
> > > here and get some so I
> > > > can look and see. Now I'm headed back out there in
> > > my ICE car.
> > > >
> > > > Anyhow, where do I get those huge fuses? Something
> > > tells me the hardware
> > > > store down the way isn't going to have them...
> > > I'll bet the electrical
> > > > supply joints are closed by now.
> > > >
> > > > Thanks
> > > >
> > > > Hunter
> > > >
> > > > _______________________________________________
> > > > For subscription options, see
> > > > http://lists.sjsu.edu/mailman/listinfo/ev
> > > >
> > >
> > > _______________________________________________
> > > For subscription options, see
> > > http://lists.sjsu.edu/mailman/listinfo/ev
> > >
> >
> >
> > Converting a gen. 5 Honda Civic? My $20 "CiviWithACord" DVD shows
> footage of my '92 sedan, as well as a del Sol and hatch too!
> > www.budget.net/~bbath/CivicWithACord.html
> > ____
> > __/__|__\ __
> > =D-------/ - - \
> > 'O'-----'O'-'
> > Would you still drive your car if the tailpipe came out of the steering
> wheel? Are you saving any gas for your kids?
> >
> > __________________________________________________
> > Do You Yahoo!?
> > Tired of spam? Yahoo! Mail has the best spam protection around
> > http://mail.yahoo.com
> >
> > _______________________________________________
> > For subscription options, see
> > http://lists.sjsu.edu/mailman/listinfo/ev
>
> _______________________________________________
> For subscription options, see
> http://lists.sjsu.edu/mailman/listinfo/ev
>
_______________________________________________
For subscription options, see
http://lists.sjsu.edu/mailman/listinfo/ev
 

·
Registered
Joined
·
70 Posts
Discussion Starter #8
Hunter,
=

Try a battery manufacturing place in your area. There is a firm in Chicago=
, Il =

that has repaired a battery post on two different batteries that I know of.=
The
charge was $10. Both batteries have been functioning well for more that t=
hree =

months.
Beano -- 1981 Ford Escort EV =

EValbum 1010Ted Sanders

> From: [email protected]> To: [email protected]> Date: Thu, 1 Nov 2007 21=
:30:19 -0500> Subject: Re: [EVDL] Arg!> > So, by the way...can I replace th=
e post on this battery? Is it likely to> have other problems? Surely it's n=
ot just toast at this point, is it?> > Thanks> > Hunter> > On Thu, 2007-11-=
01 at 19:40 -0500, Hunter Cook wrote:> > Bob-> > > > You hit it on the head=
. Wasn't a fuse...once I got the bed up and the> > cover off, I could see t=
hat one of the batteries had a melted post and a> > cap blown off. As it ha=
ppens I was at relatively low rpm in 4th gear,> > although I was going down=
hill.> > > > Anyway, while this was an expensive bit of stupidity, it was a=
t least> > easy to bypass the battery and drive home to lick my wounds.> > =
> > Thanks for the post, now at least I know how I messed up.> > > > Hunter=
> > > >
Bob Bath wrote:> > > Hunter, I d=
on't know your rig, sorry, so will offer> > > the following guesses:> > > a=
) You have a low pack voltage, so compensate by> > > pulling lots of amps. =
Getting to freeway speed is a> > > sustained pull of amps, not a short one.=
> > > b) You are in a high gear for what you're trying to> > > do (say 3rd=
at 45 up a hill, instead of keeping in 2nd> > > with lower amps, higher RP=
Ms). In my experience> > > though, this resulted in a battery terminal pudd=
ling,> > > not the fuse going... Hmmm.> > > c) You had a loose nut on the f=
use where the problem> > > occurred in the first place.> > > > > > That's a=
ll that comes to my mind...> > > Hope you figure out what the deal was.> > =
> peace,> > > > > > > > > --- Roland Wiench <[email protected]> wrote:> > > > > =
> > Hello Hunter,> > > > > > > > Call directly to evparts.com and you will =
have them> > > > over nite or in a day. > > > > Always carry spare parts in=
threes. When your fuse> > > > blows, you use one out > > > > of the spares=
, leaving two. This leave you time to> > > > reorder for stock.> > > > > > =
> > Some time we in our electrical work, will have a> > > > fuse blow becau=
se of aging > > > > or not the correct type. You want the bolt in> > > > se=
mi-conductor type which you > > > > can get from EV Parts which they have i=
n stock. > > > > Even my local electrical > > > > supply store do not stock=
the correct size, so I> > > > have to have them order > > > > them.> > > >=
> > > > I carry a complete EV tool box, that has every> > > > replacement =
part I need to > > > > repair or temporary fix the EV so I can move it. > >=
> > One time way back in the > > > > stone age, I made a temporary fuse ou=
t of ganging> > > > together 50 to 100 amp > > > > rated fuse wire and crim=
ping all the ends together> > > > with a 2/0 wire terminal > > > > to make =
a 400 amp fuse, while I waited for a> > > > replacement.> > > > > > > > I a=
lso make up many jumper cables to jump out a bad> > > > battery and if I ha=
d to, > > > > jump out the controller, and contactor drive it with> > > > 1=
/4 to 1/2 battery pack > > > > voltage driving it very slowly in low gear.>=
> > > > > > > Roland> > > > > > > > > > > > ----- Original Message ----- >=
> > > From: "Hunter Cook" <[email protected]>> > > > To: "Electric Vehicl=
e Discussion List"> > > > <[email protected]>> > > > Sent: Thursday, Novemb=
er 01, 2007 4:34 PM> > > > Subject: [EVDL] Arg!> > > > > > > > > > > > > An=
d it was all going so well...> > > > >> > > > > Got all charged up and went=
out to the hardware> > > > store, about 1.5 miles> > > > > away. It's on t=
he highway, and the truck was> > > > really accelerating pretty> > > > > we=
ll right up to 60mph...when suddenly I heard a> > > > pop from behind me an=
d> > > > > lost all my juice.> > > > >> > > > > Darn.> > > > >> > > > > I'm=
thinking (hoping) a fuse; there are two of> > > > them back there under th=
e> > > > > bed. Thought I had everything wired up nice, and I> > > > was on=
ly giving it> > > > > about 100A, so I wonder why it would blow? Anyway,> >=
> > I didn't have any> > > > > props for the bed (doh!) so I had to walk b=
ack> > > > here and get some so I> > > > > can look and see. Now I'm headed=
back out there in> > > > my ICE car.> > > > >> > > > > Anyhow, where do I =
get those huge fuses? Something> > > > tells me the hardware> > > > > store=
down the way isn't going to have them...> > > > I'll bet the electrical> >=
> > > supply joints are closed by now.> > > > >> > > > > Thanks> > > > >> =
> > > > Hunter> > > > >> > > > > __________________________________________=
_____> > > > > For subscription options, see> > > > > http://lists.sjsu.edu=
/mailman/listinfo/ev> > > > > > > > > > > > > _____________________________=
__________________> > > > For subscription options, see> > > > http://lists=
.sjsu.edu/mailman/listinfo/ev> > > > > > > > > > > > > Converting a gen. 5 =
Honda Civic? My $20 "CiviWithACord" DVD shows footage of my '92 sedan, as w=
ell as a del Sol and hatch too! > > > www.budget.net/~bbath/CivicWithACord.=
html> > > ____ > > > __/__|__\ __ > > > =3DD-------/ - - \ > > > 'O'-----'O=
'-'> > > Would you still drive your car if the tailpipe came out of the ste=
ering wheel? Are you saving any gas for your kids?> > > > > > _____________=
_____________________________________> > > Do You Yahoo!?> > > Tired of spa=
m? Yahoo! Mail has the best spam protection around > > > http://mail.yahoo.=
com > > > > > > _______________________________________________> > > For su=
bscription options, see> > > http://lists.sjsu.edu/mailman/listinfo/ev> > >=
> _______________________________________________> > For subscription opti=
ons, see> > http://lists.sjsu.edu/mailman/listinfo/ev> > __________________=
_____________________________> For subscription options, see> http://lists.=
sjsu.edu/mailman/listinfo/ev
_________________________________________________________________
Help yourself to FREE treats served up daily at the Messenger Caf=E9. Stop =
by today.
http://www.cafemessenger.com/info/info_sweetstuff2.html?ocid=3DTXT_TAGLM_Oc=
tWLtagline
_______________________________________________
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Joined
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70 Posts
Discussion Starter #9
'74 Beetle or Super Beetle? The shake is known mostly with Super
Beetles (and much older king and link pin Beetles.)

For the Super you need to use wheels with stock offset or more
positive. Many after market wheels do not have enough positive offset
(front wheel drive offset.) The front suspension must be in good
shape mechanically, no worn bushings, and properly aligned. The
wheels and tires need to be dynamically balanced, static balanced is
not good enough. Lastly, balance is so critical that you should check
the lug bolts to make sure they are the same weight. If its is a
Super Beetle the extra weight will likely make it more sensitive but
the wheel offset is usually the biggest issue.

Paul Gooch

Brian Staffanson wrote:

> You sound like you have a similar experience that I had a few weeks
> ago, in
> my little 74 VW beetle. I had taken it on several small journeys
> around my
> neighborhood. Then I decided to see if it would do the trip to
> school,
> which is 14 miles away. I decided that I would go about half way,
> and then
> return. Well, my car at around 55 mph, has a shake in the front end.

_______________________________________________
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Registered
Joined
·
70 Posts
Discussion Starter #10
Add to that a loose battery connection, or a bad battery!

Joseph H. Strubhar

Web: www.gremcoinc.com

E-mail: [email protected]
----- Original Message -----
From: "Bob Bath" <[email protected]>
To: "Electric Vehicle Discussion List" <[email protected]>
Sent: Thursday, November 01, 2007 5:23 PM
Subject: Re: [EVDL] Arg!


> Hunter, I don't know your rig, sorry, so will offer
> the following guesses:
> a) You have a low pack voltage, so compensate by
> pulling lots of amps. Getting to freeway speed is a
> sustained pull of amps, not a short one.
> b) You are in a high gear for what you're trying to
> do (say 3rd at 45 up a hill, instead of keeping in 2nd
> with lower amps, higher RPMs). In my experience
> though, this resulted in a battery terminal puddling,
> not the fuse going... Hmmm.
> c) You had a loose nut on the fuse where the problem
> occurred in the first place.
>
> That's all that comes to my mind...
> Hope you figure out what the deal was.
> peace,
>
>
> --- Roland Wiench <[email protected]> wrote:
>
>> Hello Hunter,
>>
>> Call directly to evparts.com and you will have them
>> over nite or in a day.
>> Always carry spare parts in threes. When your fuse
>> blows, you use one out
>> of the spares, leaving two. This leave you time to
>> reorder for stock.
>>
>> Some time we in our electrical work, will have a
>> fuse blow because of aging
>> or not the correct type. You want the bolt in
>> semi-conductor type which you
>> can get from EV Parts which they have in stock.
>> Even my local electrical
>> supply store do not stock the correct size, so I
>> have to have them order
>> them.
>>
>> I carry a complete EV tool box, that has every
>> replacement part I need to
>> repair or temporary fix the EV so I can move it.
>> One time way back in the
>> stone age, I made a temporary fuse out of ganging
>> together 50 to 100 amp
>> rated fuse wire and crimping all the ends together
>> with a 2/0 wire terminal
>> to make a 400 amp fuse, while I waited for a
>> replacement.
>>
>> I also make up many jumper cables to jump out a bad
>> battery and if I had to,
>> jump out the controller, and contactor drive it with
>> 1/4 to 1/2 battery pack
>> voltage driving it very slowly in low gear.
>>
>> Roland
>>
>>
>> ----- Original Message -----
>> From: "Hunter Cook" <[email protected]>
>> To: "Electric Vehicle Discussion List"
>> <[email protected]>
>> Sent: Thursday, November 01, 2007 4:34 PM
>> Subject: [EVDL] Arg!
>>
>>
>> > And it was all going so well...
>> >
>> > Got all charged up and went out to the hardware
>> store, about 1.5 miles
>> > away. It's on the highway, and the truck was
>> really accelerating pretty
>> > well right up to 60mph...when suddenly I heard a
>> pop from behind me and
>> > lost all my juice.
>> >
>> > Darn.
>> >
>> > I'm thinking (hoping) a fuse; there are two of
>> them back there under the
>> > bed. Thought I had everything wired up nice, and I
>> was only giving it
>> > about 100A, so I wonder why it would blow? Anyway,
>> I didn't have any
>> > props for the bed (doh!) so I had to walk back
>> here and get some so I
>> > can look and see. Now I'm headed back out there in
>> my ICE car.
>> >
>> > Anyhow, where do I get those huge fuses? Something
>> tells me the hardware
>> > store down the way isn't going to have them...
>> I'll bet the electrical
>> > supply joints are closed by now.
>> >
>> > Thanks
>> >
>> > Hunter
>> >
>> > _______________________________________________
>> > For subscription options, see
>> > http://lists.sjsu.edu/mailman/listinfo/ev
>> >
>>
>> _______________________________________________
>> For subscription options, see
>> http://lists.sjsu.edu/mailman/listinfo/ev
>>
>
>
> Converting a gen. 5 Honda Civic? My $20 "CiviWithACord" DVD shows footage
> of my '92 sedan, as well as a del Sol and hatch too!
> www.budget.net/~bbath/CivicWithACord.html
> ____
> __/__|__\ __
> =D-------/ - - \
> 'O'-----'O'-'
> Would you still drive your car if the tailpipe came out of the steering
> wheel? Are you saving any gas for your kids?
>
> __________________________________________________
> Do You Yahoo!?
> Tired of spam? Yahoo! Mail has the best spam protection around
> http://mail.yahoo.com
>
> _______________________________________________
> For subscription options, see
> http://lists.sjsu.edu/mailman/listinfo/ev
>
>
>
> --
> No virus found in this incoming message.
> Checked by AVG Free Edition.
> Version: 7.5.503 / Virus Database: 269.15.17/1103 - Release Date:
> 11/1/2007 6:01 AM
>
>

_______________________________________________
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70 Posts
Discussion Starter #11
U guys ever hear of a steering damper on a VW.
Rich in Va
----- Original Message -----
From: "Paul" <[email protected]>
To: "Electric Vehicle Discussion List" <[email protected]>
Sent: Friday, November 02, 2007 7:14 PM
Subject: Re: [EVDL] Arg!


> '74 Beetle or Super Beetle? The shake is known mostly with Super
> Beetles (and much older king and link pin Beetles.)
>
> For the Super you need to use wheels with stock offset or more
> positive. Many after market wheels do not have enough positive offset
> (front wheel drive offset.) The front suspension must be in good
> shape mechanically, no worn bushings, and properly aligned. The
> wheels and tires need to be dynamically balanced, static balanced is
> not good enough. Lastly, balance is so critical that you should check
> the lug bolts to make sure they are the same weight. If its is a
> Super Beetle the extra weight will likely make it more sensitive but
> the wheel offset is usually the biggest issue.
>
> Paul Gooch
>
>
Brian Staffanson wrote:
>
>> You sound like you have a similar experience that I had a few weeks
>> ago, in
>> my little 74 VW beetle. I had taken it on several small journeys
>> around my
>> neighborhood. Then I decided to see if it would do the trip to
>> school,
>> which is 14 miles away. I decided that I would go about half way,
>> and then
>> return. Well, my car at around 55 mph, has a shake in the front end.
>
> _______________________________________________
> For subscription options, see
> http://lists.sjsu.edu/mailman/listinfo/ev
>
>
> --
> No virus found in this incoming message.
> Checked by AVG Free Edition.
> Version: 7.5.503 / Virus Database: 269.15.18/1104 - Release Date:
> 11/1/2007 6:47 PM
>
>

_______________________________________________
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http://lists.sjsu.edu/mailman/listinfo/ev
 

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Joined
·
70 Posts
Discussion Starter #12
Paul, you are correct. It is a super. Maybe converting my super wasn't
such a good idea, for practical points. But it is what I have. Thanks for
the suggestions. Somebody else told me to check thesamba.com. Maybe, I can
implement these ideas when I have more funds and time...

Brian

On 11/2/07, Paul <[email protected]> wrote:
>
> '74 Beetle or Super Beetle? The shake is known mostly with Super
> Beetles (and much older king and link pin Beetles.)
>
> For the Super you need to use wheels with stock offset or more
> positive. Many after market wheels do not have enough positive offset
> (front wheel drive offset.) The front suspension must be in good
> shape mechanically, no worn bushings, and properly aligned. The
> wheels and tires need to be dynamically balanced, static balanced is
> not good enough. Lastly, balance is so critical that you should check
> the lug bolts to make sure they are the same weight. If its is a
> Super Beetle the extra weight will likely make it more sensitive but
> the wheel offset is usually the biggest issue.
>
> Paul Gooch
>
>
Brian Staffanson wrote:
>
> > You sound like you have a similar experience that I had a few weeks
> > ago, in
> > my little 74 VW beetle. I had taken it on several small journeys
> > around my
> > neighborhood. Then I decided to see if it would do the trip to
> > school,
> > which is 14 miles away. I decided that I would go about half way,
> > and then
> > return. Well, my car at around 55 mph, has a shake in the front end.
>
> _______________________________________________
> For subscription options, see
> http://lists.sjsu.edu/mailman/listinfo/ev
>
_______________________________________________
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http://lists.sjsu.edu/mailman/listinfo/ev
 
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