Some More Parts

Some more parts have arrived.
After a lot of searching a suitable DC/DC converter was located at a reasonable price.  Meanwell make a wide range of power supplies including the RSP-1500-12.  This power supply will operate on 127-370VDC and supply up to 125A at 12VDC, perfect noting the additional electrical loads for the power steering pump and the vacuum pump. The output voltage can be adjusted up to 13.5VDC to maintain the auxiliary battery at full charge.


RSP-1500-12

It also has an alarm signal that can be used to drive the original alternator warning light.
The water heater for the cabin also arrived.  Unfortunately the thermostat was damaged in transit.  It looks simple to replace and, as it was sent from the US, hopefully the supplier can provide a replacement thermostat under warranty that they would be happy for me to install.


Water Heater

Two under tray pannier boxes also arrived.  One of these will house the power cord and the other is for balance.  I plan to fit a rotary limit switch to the door to disable the motor controller if the power cord is not secured in the box.

Battery Box Design

Back into SketchUp to design a battery box. 
My first effort (Version 1) was based on 52 x 200Ahr batteries (166V) and used bars designed to fit through the corrugations in the batteries to hold them in.  This was to leave the tops of the batteries free from fittings other than the connections. 

Battery Box Ver 1 - In Situ

This arrangement fits very snugly into the front of the tray with the battery chargers fitted on the left and the contactors and BMS on the right.  The advantages of putting the chargers and contactors in the box is that the high voltage is contained within the battery box when the car is shut down. 

Battery Box Ver 1 - Frame

I think the design is too tight so I am working on Version 2 based on 180Ahr batteries, probably 58 or 60 depending on how they fit.  These batteries are slightly taller and I am hoping to gain some floor space at the cost of some height. The 180Ahr batteries should still fit in the tray without obstructing the rear window from the cab.   The higher battery voltage (approx 196V) is within the specifications of all the components I have bought so far with the exception of the water heater.  If the higher voltage turns out to be a problem I will connect the elements in series and operate the unit at a lower power output. 

Motor Mount Fabrication Begins

After a bit of a false start we started the welding for the motor mount today.
I got all the individual pieces for the motor mount cut a couple of weeks ago.  A company in Queenbeyan cut them for me using a very cool computer controlled profile cutter normally used for cutting glass and ceramics but which could also be used for steel and wood (they can cut 10mm MDF without any noticable swelling at all). 
Unfortunately in my original model I forgot to include the studs for the power cables on the side for the motor and the lower A/C mounting plate ended up being in the same place as one of the studs.  To move the mounting plates out by 25mm I added two small "fixit" bits to the front plate (shown below in white) and widened the top plates.  Lesson for first time 3D CAD modelers - model all parts of the components and ot just the major bits!  


Motor Mount Ver 2

The photo below shows the front plate with the "fixit" bits added and the power steering pump mount tacked on.


Motor Mount Fabrication

Next step is to sort the mounting arrangements for the A/C compressor and the vacuum pump which go on the other side. 

The photo below shows the main part fully welded with the power steering pump and vacuum pump fitted up.

Motor Mount Initial Fit Up