No pistons, no fuel, no worries! Toyota Sera EV Conversion begins…

[VA61DETT]

Update
Wednesday, 2 September 2009

Batteries on charge & nothing blew up whooo!!!

Pulling near on 15A from the mains socket, extension cable gets a little warm, but all good
Batteries don’t even break sweat, barely over ambient temp after 2 hours.

Power!


Temporary charge rig


The bench power-supply is for activating the charge contactor, as a safety precaution no HV is present on any connectors until 12V is supplied to the system.

Next up, mounting the ZILLA!

-A

[wagonist]

Nice

Where are you going to mount the charging connection?
I'd suggest inside the fuel filler flap. Neat, hidden, you don't need to leave a door open & makes use of what is now a redundant spot.

You could even maybe mount a retractable reel like off a vacuum cleaner in there, that'd really freak people out.

[rdorman]

Nice

Where are you going to mount the charging connection?
I'd suggest inside the fuel filler flap. Neat, hidden, you don't need to leave a door open & makes use of what is now a redundant spot.

You could even maybe mount a retractable reel like off a vacuum cleaner in there, that'd really freak people out.

haha, heaps good idea

could just imagine the expression on someones face if they tried to syphon your petrol

[VA61DETT]

Yep,
Something like that would be the plan.

-A

[SLO-030]

Imagine someone thats going to syphon the tank on this thing. Jimmies the fuel door open followed by "WTF" when they find a power point instead of a filler cap.

[thechuckster]

downside is idiot family member borrows car, runs the batteries down and tries to poor petrol into the power point.


displaying ignorance here - what are the LED units (the 'cell balance modules') on all the batteries? do they just tell you when a cell is borked, or do they so other funky things?

[Draven]

not being involved in the project, I reckon they'd make troubleshooting about a billion times easier

[marc280]

I'm pretty sure the 'cell balance modules' are there to make sure each battery doesn't get overcharged. Once they are charged to a certain point it will bypass that cell and keep charging the others.

VA61DETT, you mentioned that you bought the batteries and cell balance modules as a package, you mind if I ask where you got them from?

[VA61DETT]

Hi,

The cell modules are basically individual voltage monitors, they are connected to a controller which will automatically flag an error & shut off the power in the case of cell over / under voltage conditions.
They certainly will make it much easier to see if there are any problems at a glance, (led's light red if there is a problem).

I bought the complete battery system from :http://www.evpower.com.au/

-A

[VA61DETT]

Updates!
Tuesday, 22 September 2009

Had a productive weekend, routing the high voltage cables & installing the controller box.
I scored the funky IP rated box from my local scrap metal dealer, including the 2 little ammeters, which I may rig-up for accessory current monitoring.

Test fitment of zilla box & accs


Bonnet clearance, No worries!



Close up of Zilla business end & 0000 cable


I would have liked to use the quad 0 cable for connection between the Zilla and motor, but it was going to be just too tight, so I had to settle with 00 gauge instead…(oh nows teh voltage drops!!11)

00 Cable, Its pretty big….


I routed the cable through the ‘tranny tunnel’ conveniently there were plenty of captive nuts from the old exhaust heat shield mounts. It was just a matter of making up several clamps to suite.
The most difficult part was getting the orange conduit to bend tight enough to fit.
With a bit of perseverance & a heat gun we had a win!

Cables are in!


Getting close!!
Just need the following to make it run:
• Terminate 350A Anderson plug
• Rig up zilla TPS
• Connect ignition / start switches to zilla
• Install DC-DC converter for 12V systems
• Put drive shafts and seals in
• Fill gearbox oil
• Bolt steering wheel back on

Stay tuned!
-A

[RA35GT]

Then skids? WOOT

[brett_celicacoupe]

wow,

not far now. make sure you get vids of it going!

[MR 1JZ]

looks like I found this thread at the right time

subscribing for electroskids

[VA61DETT]

Mahha, Yes there will be Leccy skids vids!
Hmm maybe motorvation 2011 entry ;D

-A

[RA35GT]

First electric car on the burnout pad?!?