Now that the high voltage electrical is starting to look good, I figured it was time to start cleaning up the 12 volt side of things. I made a fuse/relay board to mount everything to:
The weather has finally started to change and today was the first day I need to move my car while it was raining (there is a short drive from my storage container to the shop). I didn’t want my electronics to get wet so I used a little shrink wrap to make a windshield and trunk lid:
It may not look so in the picture, but my shrink wrap windshield is quite easy to see through.
All the high voltage electronics are now neatly mounted on the rear tray. In the process of remounting everything, I removed a lot of excess wire to clean everything up:
My goal is to make the tray removable to enable easy access to all the electronics. To make this work, I need to “connectorize” the pack, the motor and all the low voltage control lines. My plan is to get two beefy Anderson connectors (one for the battery pack and one for the motor) and some kind of multiconductor bayonet connector for all the low voltage lines…
Here’s a couple pictures I took a while back, but didn’t include in previous posts.
This is a shot of the roll cage/body mount:
As you can see, I still need to weld the last piece to attach the windshield pillars to the chassis.
Here’s a shot of my LED tail lights:
It’s been two weeks since I have posted an update so there is lots of progress to report.
1. The BMS version two is up and running with a single MAX6802 (I should be getting some more chips any day now). There is just one bug I need to figure out. The last battery in the chain is reading 0 volts. All the others read fine. This could be because it is supposed to be wired up to the next string which isn’t installed yet. However, I think there might be something else going on. We’ll see…
2. I welded up a new aluminum mounting bracket for all the high voltage electronics.
This tray will be the final mounting location for everything that uses full pack voltage; motor controller, charger, etc… It will be accessed from the rear hatch:
3. I remounted and started the process of re-wiring all of the high voltage electronics. I am mounting everything to a piece of polycarbonate which then bolts to the aluminum bracket I made.
4. I installed my new 500amp 50mV shunt. This should give me better readings than the previous 1200amp 50mV shunt.
5. I received and tested all the LED lighting for the car. These will replace the standard incandescent backup lights, turn signals, brake lights, and side markers.
6. I cut out the safety cover for the battery box. It is 1/4″ polycarbonate. Later I will figure out the best way to vent it.
