Build Session 20 (60 mins): Started Prepping Battery Racks for Paint

Finding time to work on my truck lately still seems to be few and far between...

However, I was able to fabricate and weld in a final battery rack support member between the two forward battery racks.

I plan to epoxy coat (paint) the entire frame with POR15 rust protector and chassis coat. I'm currently prepping the frame by removing the rust, dirt, etc...

I'm pretty busy of the next few weeks but I hope to complete the prep work and rack painting by mid November.

Ordered a Zilla Z2K Controller Today!

Zilla Controller

I first discovered the Zilla controller a few years ago when I began my EV conversion research. Ever since then I have been drooling over its rich feature set and performance capabilities.

My decision to upgrade to lithium batteries (LiFePO4) has given me new reasons to pondered the idea of upgrading my 144v Curtis Controller to a Zilla controller because of it capabilities and features. Specifically I want to be able to programatically shut the controller down when any of my Thunder Sky Cells reach their minimum voltage range. This will allow me to protect the cells from under-running damage. In addition, the Zilla will allow me to run higher voltage which means better performance.

Recently I discovered that Otmar who is the founder of Cafe Electric (makers of the Zilla controller) plans to sell the Zilla rights and stop production. So I decided that I'd better buy one before they are completely unavailable and/or even more expensive. The only downside is that it will take 6 to 8 months before my controller will arrive. Once my Zilla arrives I plan to move the Curtis controller to my Porsche 914.

Hmmm.... Now I need a TransWarp 11 motor with direct drive shaft. Then I can eliminate my transmission altogether and really make this truck peppy!

Build Session 19 (180 mins): Forward Battery Rack Complete, Welding Supports

I completed the battery racks today!

Welded the six supports in place...

The completed forward battery racks...

The rear and forward battery racks...

LiFePO4 Thundersky Batteries and a PFC50B Manzanita Micro Charger

I have decided to go ahead and order 45 Thundersky Lithium Iron Phosphate (LiFePO4) Batteries. My plan was to purchase directly from Everspring.Net in China as I was unable to locate a competitive source of Thundersky cells in the U.S. until recently. However, I am currently working with Manzanita Micro and have ordered their amazing PFC50B charger, LT5B Regulators, and they are building me some custom cell under running detection hardware. In addition, they have agreed to provide me with Thundersky cells at a discount which also allows me to avoid the hassle of dealing with importing the batteries through customs.

So far, I highly recommend this company as their chargers appear to be superior to anything else that I have researched. Clarice (sales) and Stephen are extremely helpful in answering my pre-sales questions (Warning: Don't send too many questions to Rich though...he can be a bit grumpy).