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Discussion Starter #1
We are at the stage of our build where we are making up harnesses and connectors to our contactors and controller.

I have seen a few cars with "black boxes" full of connections but I am wondering what others are using to make connections.

It seems like terminal strips are not the best for an exposed application. Are weather-pack connectors a good way to go?

(We have 9 EV200 contactors with position contacts for a total of 36 connections to make, plus the controller wires to the key switch, all going under the dash about 6 ft away)

Thanks
 

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We are at the stage of our build where we are making up harnesses and connectors to our contactors and controller.

I have seen a few cars with "black boxes" full of connections but I am wondering what others are using to make connections.

It seems like terminal strips are not the best for an exposed application. Are weather-pack connectors a good way to go?

(We have 9 EV200 contactors with position contacts for a total of 36 connections to make, plus the controller wires to the key switch, all going under the dash about 6 ft away)
Hi Tah,

Why in the world would you have 9 Kilovacs?

On the control wiring, terminal strips are nice for your first go-around. Lets you change things easily and gives you test points to check when stuff happens you don't expect, or vice versa.

For the road worthy edition, I use Delphi Packard Metri-Pack connectors. Like these: http://order.waytekwire.com/products/M50/320/550/400/11 This gives you a weather resistant automotive look easy to assemble, route and disassemble.

In enclosed areas and to mate with Curtis and Sevcon controllers, I use Molex Mini-Fit Jr plugs, pins and sockets.

On high end stuff (and high voltage) I use Cannon metal shell Mil style connectors. But these are expensive. These are available for signal and power lines.

For regular power connectors, I use Anderson Power Products. SB style.

Regards,

major
 

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Discussion Starter #3
I'll look into your suggested connectors.

Maybe you don't remember but I'm doing the dual 7 inch motors with electric two speed and electric reverse. I might have sent you my schematic privately some time back.

I have three for low/high speed, four for forward reverse, and two for battery plus and minus:

View attachment Dual Motor EV200 reverse and series parallel.pdf

Here's a sneak peek of the motors mounted in the Wombat
 

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Maybe you don't remember but I'm doing the dual 7 inch motors with electric two speed and electric reverse....I have three for low/high speed, four for forward reverse, and two for battery plus and minus:
Oh yeah. Didn't recall the S/P switch. :cool::cool:

That is a lot to get sorted out on the first try. And would be a heck of a harness. Maybe a combination of Metri-Pack connectors and a terminal junction box would work best.

When I wire up something like this, typically, I have like 10 colors of #18 wire. And after assembling the plugs and connectors, I dress it up using split loom and tape. You can even get colored loom to make it look neat.

I keep a list of wire colors and plug/pin IDs referenced to the wiring diagram. This helps keeping everything straight and chasing problems. A label maker comes in handy :)

major
 

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Discussion Starter #6
No junkyard parts on this one. The interlock HAS to work perfectly or bad things happen.

Major,
Actually, the whole thing is wired up to terminal strips and documented. I don't like the strips and want take it up a notch.

Everyone,
I wired up the motors and contactors with #16 wire to test it out before making up the 2/0 connections. I now have a set of patterns for the 2/0 and can order just enough to wire it all up. I will snap pictures if anyone is interested...
 

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whats wrong with covered spade connectors for the little stuff? I put terminal strips inside a custom shape weather-proof area w/ clear lid. The base and 'box' I used 1/4 thick polypro I used for battery boxes and heat-welded. I put the sensitive stuff n a covered area, and heat-generating stuff in the open, but all mounted on the base so I can take out the whole thing undoing a few connectors if need be.
 

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Discussion Starter #8
dt,
if you look at the plate in the picture, the nine ev's are mounted vertically along the motors, 4 on one side and 5 on the other. I need to run a harness to the dash to interface to the control relays.

When you say terminal spades are you thinking about landing everything on a screw type terminal bus? My test setup is that way and 50 terminations is spread out pretty wide.

I'm thinking about going with (9) 4 terminal connectors the major suggested. I've used those before and hated the tedious make up time but maybe I'll have one of my guys do it this time. :)
 

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Actually, the whole thing is wired up to terminal strips and documented. I don't like the strips and want take it up a notch.
...
Tahoe,

Sounds like you got a nice professional project going there. Here is another type of connector I've used. And really nice. http://www.laddinc.com/our-products/online-catalog/itemlist/category/4131-dt series.html

Years ago, I tried to standardize on one connector system. Went with Amp CPC. Got a good inventory and crimp tool. Then things change. And had to use this plug. Or that. Great thing about standards.....there are so many to choose from :)

Looking forward to seeing the finished product ;)

major
 

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dt,

I would like to know more about heat welding. I have a need for some custom work. Any suggested links to learn about it?

there is a little at the manufact website, but not much. It is a lot like TIG/MIG welding except you lay in steady bead along seams with a rod of matching material. I have only used it to create box edges on battery box and component box. pretty easy. the 'good' welders are pretty expensive, but probably worth it in durability and variable heat setting. You can heat-weld Polypro, HDPE, and ABS.
 

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You could also scavenge connectors from a junkyard.
Hey jeremy,

Nothing wrong with re-use. I have done plenty of that. Especially with power connector housings. Even reused wire when I had to. But when you have spent 1000s for motors, controllers, contactors, etc.......you want the wiring to stand out excellent. Nice, new, shinny.... :):)

major
 
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