ELECTRIC CAR PROJECT 9311 DIARY, FEB 96
Painted throttle cable brackets. Applied heat sink compound to the
bottom of the DC-DC converter and mounted it on the front accessory
mounting plate. Also mounted charger. Installed in car. Connected
Rubbed off some adhesive residue in engine compartment.
Rubbed off some more adhesive residue in engine compartment.
Rubbed off some more adhesive residue in engine compartment. Removed
wire bundle from tie downs and cleaned out the engine compartment.
Wired the pot/relay assembly.
Updated the wiring diagram with the colors of the wires used on the
pot/relay assembly. Resecured the wire bundle. Reinstalled the front
and rear floor plate brackets in the engine compartment.
Picked up (at Tacoma Screw Products) some 7/8" long grade 5 zinc
plated hex head cap screws for use assembling the engine compartment
parts. The 3/4" long screws that I already had were too short when
used with washers. For the same reason, decided to not use washers
on side and back pieces.
Installed left floor plate and side.
Installed pot/relay assembly mounting bracket. Installed connector
on rear fan cable. Front fan should mount on right rear of battery
box. Vent from left front through floor behind windshield washer
Made a miter box out of wood and cut the heatsink in half (18") with
the hacksaw. Painted cut off end with black touchup paint.
Located and drilled four 17/64" holes in the right-side floor plate
for mounting the heatsink. Drilled four matching #7 holes in the
Tapped (1/4-20NC) the heatsink mounting holes. The heatsink weighs
6-1/2 pounds. Installed the engine compartment side piece on the
right-side floor plate. Applied heatsink compound to the controller
and mounted it on the floor plate. Installed the contactor. Applied
heatsink compound to the heatsink and installed. Installed shunt.
Installed the right-side floor plate assembly in car and connected
the motor cables to the motor. Tightened all bolts.
Installed the engine compartment front plate. Relocated the shunt a
few inches forward. Made a new shunt to S1 cable. Installed the
pot/relay assembly. Routed wiring.
Installed the engine compartment back piece. Cut the wires from the
pot/relay assembly to length. Installed crimp on terminals. Routed
and connected most of the wires. Cut cable ties off battery cables.
Removed the rightmost original-equipment cable tiedown at the front
of the engine compartment, enlarged it's mounting hole to 11/32" and
installed a 1/4" rivet nut. Then installed a small bracket made from
3/4" aluminum angle with a 1/4" bolt. Secured the battery cables to
the bracket with a cable tie. Installed the rest of the cable ties.
Installed trasmission throttle cable bracket and clamp. Added a new
clamp on the throttle cable assembly just behind the battery rack
attached with 10-32 screw and 10-32 rivet nut. Repositioned the
throttle cable assembly. Made a longer link to connect the throttle
cable to the bell crank.
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