Chevy Volt and Electric 3 series BMW (Ev-36/46)

I'm hoping by end of christmas break at the latest to have the EV moving on it's own power even if on ony 7 batts. Progress so far. Most of the high voltage lines are done. I need to make 3 more. Still haven't finished the return lines on the PS so that's left and then wire up the Hair ball. See how much longer that takes. Here are a few more part#'s and stores I bought from. Contactor: Kilovac EV200 Contactor. Purchased from E-bay Crimping tool: Lengo Swedg-on Tool Model 840 From E-bay Fuses and Heat shrink: purchased from EV Source LLC www.evsource.com 1ft Length, 1in Normal Adhesive Lined Heat Shrink Tubing, Red Item# 600-HSA-001-RE-N 3ft 1ft Length, 1in Normal Adhesive Lined Heat Shrink Tubing, Black Item# 600-HSA-001-BL-N 3ft 500A 300VDC fuse, Up to 1000A Controller up to 276V Nominal System Voltage Item# 201-A30QS500-4 qty 2

I added the supports for the batteries on the tray that goes above the motor. That finished of my Argon gas for welding and had to get a refil. I think I'll use less now that I know what i'm doing. Started making battery cables. I played with soldering them on. I had thought of soldering AND crimping. However the fit of the lug to the wire was snug so inserting the wire with a heated lug didn't work well. So I'm just crimping. Using the hammer crimper in the press works very easy. Seems to be working well but I have no other experience with this type of work to compare it with. I also cleaned up or rather filed off some of the ugly welds. I need to re weld some of the bad ones. I'll also add some gussetts and some minor touchups. A real nice part is I won't have to paint it

More progress on the front battery tray. Added most of the upper tray above the motor. Spent most of saturday on it. Seems like I should have made more progress but it takes time. Also learning a new skill of welding aluminum does slow me down some. Some welds are great and some are horrid. I'm having a hard time telling what makes the difference. More practice is needed. Took a picture of my helper standing on the battery rack. Thought it would make a funny picture. Of course he reminded me that he only weighs what one battery weighs. So I stood on them. Seemed plenty strudy and so far the rack weighs less than 15 LBS. The mail man dropped off the fuses and heat shrink tubing. The wire lugs arrived earlier this week so I now have enough parts I should be able to make the car drive around the yard. Just some assembly required. Thaniel

Since I wanted to build battery trays out of alumiunm I purchased the materials needed to convert my MIG welder over to weld aluminum. After an evening of frustrating attempts at welding I did some more reading and found I had the heat setting all wrong. Today I managed to actually join some metal. Made a little progress on the front battery tray. There will be 4 batteries on the lower level. 2 on the passenger side of the motor one on the driverside and one inbetween. I need to add a tray to hold three batteries above the motor and more car to tray supporting structure. The lugs I ordered are suppose to be here monday. The fuses I ordered I have no clue. Maybe in a few weeks it can move under it's own power.

Got the clutch working today. Apparently to bleed this clutch system the slave cylinder has to be removed from the trans and tilted to have the bleed valve up. Weird. Did that and the clutch now works. Am behind on ordering things. Lugs and welding equiptment for welding aluminum are finally now on order. Looking at what guages I needed and found that the zilla will Display motor current on the tach. Interesting. Do I even need a battery current Ammeter? I think for now I'll go sparse on guages and add later but before it hits the road. My Goal right now is to put it together enough it'll drive in and out of the garage. So a lot of the guages and such can wait. Next steps will be: 1. Make front battery trays 2. Mount Controller and wire up hairball 3. Wire up front batteries Ok you tube is done. Video is http://www.youtube.com/watch?v=YiOYDu8Rk3M

Well here is the motor mount. It attaches to the 2 side bolts on the motor and 2 of the front bolts. I'm attaching it to the crossmember using using 2 existing holes. I used 2 rubber transmission mounts instead of motor mounts as they are smaller and this motor is lighter than the gas engine. I also didn't go with the ICE engine motor mounts and locations as I wanted to leave room on the side of the motor for another battery. I think it turned out well. Location is good being Dead center and level. Oh wire arrived today. Looks nice and beefy (4/0) and is quite flexible. I need to select and find a place to buy the fuse, circuit breaker and shunt. The motor mount I think will work out great. I am a mechanical engineer and use to design weldments as a job years ago. Did not do any analysis on this structure, other than rough numbers for the force that'll be applied at the mount points, but it should be plenty strong. And small is light and more room for the batteries. Oh...

I was looking around and found some tinned lugs with the right bolt hole in them for a reasonable price. Think I'll just order them. I have my motor mount bracket just about done. Painted it last night. will have to get some pictures and post it. Went a little different way than what I have seen most do.