Electric conversion: Project ForkenSwiift - Page 75 - Fuelly Forums

Android Users - Coming Soon! - Migrating from aCar 4.8 to 5.0

Reply
 
Thread Tools Display Modes
 
Old 09-16-2007, 07:19 PM   #741
Registered Member
 
MetroMPG's Avatar
 
Join Date: Dec 2005
Posts: 4,223
Country: United States
Also, I made a cable end lug with coarser strand 3/0. It didn't turn out quite as well as the fine strand stuff - more prone to cracking when flattening/drilling as I suspected it would be. But it worked OK.
__________________

MetroMPG is offline   Reply With Quote
Old 09-17-2007, 09:17 AM   #742
Registered Member
 
Join Date: Aug 2007
Posts: 34
Country: United States
Send a message via ICQ to GasSavers_BigMouse Send a message via AIM to GasSavers_BigMouse Send a message via MSN to GasSavers_BigMouse Send a message via Yahoo to GasSavers_BigMouse
Quote:
Originally Posted by MetroMPG View Post
Also, I made a cable end lug with coarser strand 3/0. It didn't turn out quite as well as the fine strand stuff - more prone to cracking when flattening/drilling as I suspected it would be. But it worked OK.
I ordered myself 30 feet of 3/0 welding cable (fine stranded stuff). Hopefully I'll get enough area out of the end to drill the 1/2" holes for the lugs on the motor. I may just have to splurge on the the 6 or so cable ends I'll need. NiCad battery cells use solid interconnects, not cables, so I won't have all that many to do. Good info though!
__________________

GasSavers_BigMouse is offline   Reply With Quote
Old 09-17-2007, 09:23 AM   #743
Registered Member
 
MetroMPG's Avatar
 
Join Date: Dec 2005
Posts: 4,223
Country: United States
You should be able to get the area for 1/2 in. holes. It's up to you really - how much you flatten the end before/after dipping it in the "solder pot".

How much voltage have you collected so far?
MetroMPG is offline   Reply With Quote
Old 09-17-2007, 09:30 AM   #744
Registered Member
 
MetroMPG's Avatar
 
Join Date: Dec 2005
Posts: 4,223
Country: United States
Added a refinement to the end-making DIY:

You don't have to pre-fill the solder pot/crucible. You can just feed solder into the side of the cable at the neck. It's heavy - it'll run down the strands as well as up.
MetroMPG is offline   Reply With Quote
Old 09-17-2007, 06:34 PM   #745
Tuggin at the surly bonds
 
Silveredwings's Avatar
 
Join Date: Apr 2006
Posts: 839
Country: United States
Quote:
Originally Posted by MetroMPG View Post
For someone with a lot more voltage & power in their pack, it's a problem.
Like a KillaSwift?
__________________
Reality is merely an illusion, albeit a very persistent one. - Albert Einstein
Silveredwings is offline   Reply With Quote
Old 09-17-2007, 06:54 PM   #746
Registered Member
 
MetroMPG's Avatar
 
Join Date: Dec 2005
Posts: 4,223
Country: United States
Yep! 'Cept that wasn't controller failure, that was full-on wetware failure!

Fortunately, neither he nor the bike (nor the minivan) were really hurt.
MetroMPG is offline   Reply With Quote
Old 09-17-2007, 07:13 PM   #747
Registered Member
 
trebuchet03's Avatar
 
Join Date: Mar 2007
Posts: 812
Country: United States
Send a message via AIM to trebuchet03
Quote:
Originally Posted by MetroMPG View Post
The reason for the pedal-actuated contactor is: in case of controller failure, the driver's first instinct is to release the go pedal, theoretically cutting power pretty much instantly (assuming it doesn't weld). If we omit it, then a split second is lost, before jamming down the clutch pedal to mechanically shut things down.
Is this a problem? I've done a bit of EV reading (likely not as much as you) and I haven't come across a "WOT" controller failure (yet).

So theoretically, turning the ignition off (in this worst case scenario controller failure) would do the same thing on an ignition based contactor. I know, split second reaction time lost....

So is it really a problem?
__________________
Time is the best teacher. Unfortunately it kills all its students.


Bike Miles (Begin Aug. 20 - '07): ~433.2 miles

11/12
trebuchet03 is offline   Reply With Quote
Old 09-17-2007, 08:26 PM   #748
Registered Member
 
Join Date: Aug 2007
Posts: 34
Country: United States
Send a message via ICQ to GasSavers_BigMouse Send a message via AIM to GasSavers_BigMouse Send a message via MSN to GasSavers_BigMouse Send a message via Yahoo to GasSavers_BigMouse
Quote:
Originally Posted by MetroMPG View Post
You should be able to get the area for 1/2 in. holes. It's up to you really - how much you flatten the end before/after dipping it in the "solder pot".

How much voltage have you collected so far?
I'm up to about 68 volts worth. About half way there :-)
GasSavers_BigMouse is offline   Reply With Quote
Old 09-18-2007, 05:02 AM   #749
Registered Member
 
MetroMPG's Avatar
 
Join Date: Dec 2005
Posts: 4,223
Country: United States
Quote:
Originally Posted by trebuchet03 View Post
Is this a problem? I've done a bit of EV reading (likely not as much as you) and I haven't come across a "WOT" controller failure (yet).
You know, in the year and a half I've been following the EVDL, 2 Cursit failure stories jump to mind (there are undoubtedly more) - and they were "fully closed throttle" failures.

I haven't actually read about a WOT controller failure, though I'm sure if you ask on the EVDL, you'll get some.

Still, everyone insists controllers will fail fully on, and they're basically ticking time bombs...
MetroMPG is offline   Reply With Quote
Old 09-18-2007, 06:07 PM   #750
Registered Member
 
MetroMPG's Avatar
 
Join Date: Dec 2005
Posts: 4,223
Country: United States
Note re. controller failures: DC controllers may fail ON. Apparently this is one of the other benefits of AC, which fail OFF.

---

Clack, clack, clack! I hooked up a second, identical contactor, this one not bolted to the unibody, and it's much more reasonable in terms of noisyness. Still louder than nothing, but nowhere near the volume of the shock tower mounted one ... probably acceptable.

So it looks OK if we can soft mount the pack +ve contactor and run it off the low pedal potbox microswitch. I'll probably still try to insulate it to keep it as quiet as possible...
__________________

MetroMPG is offline   Reply With Quote
Reply

Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off


Similar Threads
Thread Thread Starter Forum Replies Last Post
Fuelly Android App - eehokie Fuelly Web Support and Community News 2 07-14-2010 09:59 PM
Combined totals of all my vehicles? nizationpcs Fuelly Web Support and Community News 0 03-30-2009 07:41 AM
Vehicle Notes pb Fuelly Web Support and Community News 4 10-08-2008 12:38 PM
Converting numeric to current tire sizes. omgwtfbyobbq General Maintenance and Repair 5 06-01-2007 05:51 AM
Prius. First Impressions zpiloto General Fuel Topics 17 09-03-2006 11:49 PM

Powered by vBadvanced CMPS v3.2.3


All times are GMT -8. The time now is 12:57 PM.


Powered by vBulletin® Version 3.8.8 Beta 1
Copyright ©2000 - 2017, vBulletin Solutions, Inc.