tag:blogger.com,1999:blog-82448151553694954352024-02-19T17:20:45.120-08:00Kurts Chevy S-10 Conversion to ElectricThis was my first EV project. Its a 1998 Chevy S-10 that I converted to an <b>electric vehicle</b> (EV).
I documented each build session of the conversion here and I and marked each EV conversion post with the session number and time.
(For my latest project see <b>http://KurtsDodgeChallengerEV.blogspot.com</b>)Unknownnoreply@blogger.comBlogger36125tag:blogger.com,1999:blog-8244815155369495435.post-41993315907122600022010-05-16T00:30:00.000-07:002010-05-16T00:30:57.361-07:00IT'S ALIVE!!!<div class="mobile-photo"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQikbIvyFbdXcxlpfieNgZ4JBv5ZO3hl5WSyZlP0k6kBTzkIxVu0esgSnNpGnigcd4VVA_vZ-sqOjz8NUtE8hbXnPfaINiQRnwLpZe3Yafyx6Z-xGmMIUST6kWUTdclwnDd3jTNLtC_iI/s1600/image-714879.png"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5471766061894878274" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQikbIvyFbdXcxlpfieNgZ4JBv5ZO3hl5WSyZlP0k6kBTzkIxVu0esgSnNpGnigcd4VVA_vZ-sqOjz8NUtE8hbXnPfaINiQRnwLpZe3Yafyx6Z-xGmMIUST6kWUTdclwnDd3jTNLtC_iI/s320/image-714879.png" /></a></div><div class="mobile-photo"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjkfa3syh7QtPu7XgSnTrlux2mnMVVoQXDRQjBxiE6F2NvIs_Zb8j9fMyrMgFj5XmZ-RpHbvVNT8sr3Lqateo9aCKf3i135PEijf1m793YC-Lr6EQvUo_8UVP55IZaRIZ3xdzcdAXZXkB8/s1600/IMG_0845-716505.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5471766073418786306" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjkfa3syh7QtPu7XgSnTrlux2mnMVVoQXDRQjBxiE6F2NvIs_Zb8j9fMyrMgFj5XmZ-RpHbvVNT8sr3Lqateo9aCKf3i135PEijf1m793YC-Lr6EQvUo_8UVP55IZaRIZ3xdzcdAXZXkB8/s320/IMG_0845-716505.JPG" /></a></div>Yes, my EV is actually running!<br />
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<br />
A little peek under the hood...<br />
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I know that it has been an extremely long time since my last post...all I can say is work is crazy and any free time that I have was spent getting this EV running.<br />
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I have lots of great people to thanks including Stephen from HPEV, South Seattle Community College (Murray and class), and good friends Chad and Jared.<br />
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I plan to post a lot of content to this blog in July during my vacation.<br />
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Sent from my iPhoneUnknownnoreply@blogger.com5tag:blogger.com,1999:blog-8244815155369495435.post-74490664841298762292009-07-11T12:20:00.000-07:002009-07-11T13:16:36.640-07:00Build Session 24 (180 mins): Drilling and Mounting the Adapter PlateThis weekend Jared and I broke away from work long enough to drill the <br />
six mounting bolt holes in the adapter plate. Then we mounted the <br />
steel adapter coupling with the key pin and a bolts. After that we <br />
attached the spline assembly.<br />
<br />
I ordered the adapter plate assembly from <a href="http://www.ev-america.com/">EV America</a>...primarily because they were the only ones at the <br />
time that were selling a clutch-less adapter plate design. I like the concept of a clutch-less design because every pound of rotational weight equally approximately 100 pounds of total weight. So reducing <br />
rotational weight should extend the overall range of my EV.<br />
<br />
<div style="text-align: center;">Jared drilling the first hole...We're using a 1/2 in corded drill with a 31/64 drill bit.</div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgq4hfhrw1iVpnEIGDPcuwhTkjRA6dPL7ChdhKXoZSSZwKkNyKew2aoRROlPOmcNt9xpKYd_7nENLGMjT-6UpvtIZs6hR5vMdtUtatWmMQoi22sNOpgPjdSF9n9Xv-kspbqANWvQexGG5U/s1600-h/Mounting+the+Adapter+Plate+002.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgq4hfhrw1iVpnEIGDPcuwhTkjRA6dPL7ChdhKXoZSSZwKkNyKew2aoRROlPOmcNt9xpKYd_7nENLGMjT-6UpvtIZs6hR5vMdtUtatWmMQoi22sNOpgPjdSF9n9Xv-kspbqANWvQexGG5U/s320/Mounting+the+Adapter+Plate+002.jpg" /></a> </div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhLX0Y0MDh_iQZRtrys3lUWOtTJ70lFw1r1DzoqST8bnx20P7vY1_bGCQE8k-XrontawiS1PIZt7DPDS2ZzMbKNVSPh5G6LpTplWCA2WuuhXefTfypQV3c7EtzeWdZ9QFTxeGG28FUKHVs/s1600-h/Mounting+the+Adapter+Plate+004.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhLX0Y0MDh_iQZRtrys3lUWOtTJ70lFw1r1DzoqST8bnx20P7vY1_bGCQE8k-XrontawiS1PIZt7DPDS2ZzMbKNVSPh5G6LpTplWCA2WuuhXefTfypQV3c7EtzeWdZ9QFTxeGG28FUKHVs/s320/Mounting+the+Adapter+Plate+004.jpg" /></a> </div><div class="separator" style="clear: both; text-align: center;">We used a fair amount of aluminum cutting oil to speed our progress and save our bit... </div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjAEeMlt3gZDbUNt4YHbDBmkENBme6u8UdMnOQwZ9LQS4XRcvpEfsZFW1l86Cp1DgRRA_PYma7dXjg9AseMoE5vbMqNIF0QJyVXowICf1MAYfI7zVwTHvzKqAOFrU4kzwKdyYkzn7nHJHI/s1600-h/Mounting+the+Adapter+Plate+007.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjAEeMlt3gZDbUNt4YHbDBmkENBme6u8UdMnOQwZ9LQS4XRcvpEfsZFW1l86Cp1DgRRA_PYma7dXjg9AseMoE5vbMqNIF0QJyVXowICf1MAYfI7zVwTHvzKqAOFrU4kzwKdyYkzn7nHJHI/s320/Mounting+the+Adapter+Plate+007.jpg" /></a> </div><div class="separator" style="clear: both; text-align: center;">After drilling each hole we bolted it together to ensure that the adapter plate wouldn't move. To connect the adapter plate I purchased 4 9.8 grade 80mm M12 bolts, nuts, washers, and lock washers and 2 100mm bolts. I plan to use the longer ones to attached torque rods if needed.</div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhA_UZxiia0xdYr6g0MzWgJMud5ggF4BOs0XgeKQ3PTstB6cz6NRxQ8v03CqX5YSSBohpEDR6IDbrnPYurhaXxjp4-ata2pzVnZD_EaX8AosROhbSpIzATjHGFR9HnTklTFNq1fuZBNC7k/s1600-h/Mounting+the+Adapter+Plate+012.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhA_UZxiia0xdYr6g0MzWgJMud5ggF4BOs0XgeKQ3PTstB6cz6NRxQ8v03CqX5YSSBohpEDR6IDbrnPYurhaXxjp4-ata2pzVnZD_EaX8AosROhbSpIzATjHGFR9HnTklTFNq1fuZBNC7k/s320/Mounting+the+Adapter+Plate+012.jpg" /></a> </div><div class="separator" style="clear: both; text-align: center;">After drilling the first four holes and bolting each to the bell housing, we removed the C clamps and drilled the remaining two holes.</div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjFGM2PZ_5-Aeu7U_DvxyxSGrm63c-t9XF8WDTUWYXollv1oOL_fyqZxkdYvCy7Gc1jKhsjqhHiMow5a5WqiaAY0HAmQ_YT2AG3fqiYX9OlLrKODv5qN3RwRWKLbXSqXf_BV4ojMYb2Cek/s1600-h/Mounting+the+Adapter+Plate+017.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjFGM2PZ_5-Aeu7U_DvxyxSGrm63c-t9XF8WDTUWYXollv1oOL_fyqZxkdYvCy7Gc1jKhsjqhHiMow5a5WqiaAY0HAmQ_YT2AG3fqiYX9OlLrKODv5qN3RwRWKLbXSqXf_BV4ojMYb2Cek/s320/Mounting+the+Adapter+Plate+017.jpg" /></a> </div><div class="separator" style="clear: both; text-align: center;">Drilling complete... </div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjSkEl6EhuOaiuy0Vr9QRO4OCfTwokXJU1_URT6JBRGtfRFWqL36wlSzSymJU4eYfbrcsFhBOaPRUGSbrkgs7kNn2lSsVL7SzauPBZMGsDS2YIDbmUyElJ4ME5zSme3FOBgyNEg13dnjL4/s1600-h/Mounting+the+Adapter+Plate+018.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjSkEl6EhuOaiuy0Vr9QRO4OCfTwokXJU1_URT6JBRGtfRFWqL36wlSzSymJU4eYfbrcsFhBOaPRUGSbrkgs7kNn2lSsVL7SzauPBZMGsDS2YIDbmUyElJ4ME5zSme3FOBgyNEg13dnjL4/s320/Mounting+the+Adapter+Plate+018.jpg" /></a> </div><div class="separator" style="clear: both; text-align: center;">After that we removed the adapter plate and disassembled the hub assembly from the adapter plate by knocking out the long pins. <a href="http://ev-america.com/">EV America</a> ships the coupler disk, steel hub, and adapter plate pinned together with long pins to ease alignment for marking and drilling. Now its time to remove the long pins and replace them with short pins that hold the couple disk and hub assembly together only.</div><div class="separator" style="clear: both; text-align: center;">KIDS PLEASE NOTE: Flip flops are NOT appropriate protective clothing for working on electric vehicles! At least I have safety glasses on. :)</div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh_syDWke55PHkKW5wHWZUxnkfzA-hRIjjPgkU-pxAlnNIciaDrFpL3yj4ad8cWBzws9Ln5J88tn4gFdS08YHOEyieTiVfMnOvoJVogBWoNaE-j9Xp1_LFi4QawJG2M5JKdiTgZY7oqK3E/s1600-h/Mounting+the+Adapter+Plate+024.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh_syDWke55PHkKW5wHWZUxnkfzA-hRIjjPgkU-pxAlnNIciaDrFpL3yj4ad8cWBzws9Ln5J88tn4gFdS08YHOEyieTiVfMnOvoJVogBWoNaE-j9Xp1_LFi4QawJG2M5JKdiTgZY7oqK3E/s320/Mounting+the+Adapter+Plate+024.jpg" /></a> </div><div class="separator" style="clear: both; text-align: center;">Then inserted the coupler disk hub assembly over the spline transmission shaft and took some measurements with the digital calipers. This measurement helped us to figure out where to bolt the steel hub on the motor shaft. </div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEill1cFPeoFf6Xr4dvqBZex7ww2xz38kDlX_X99bE76oblDxNgR45GxtEFGctAIve89eLJ4gR8TdaP5eW-WpnFU2S2dKB56yW_fCLjFbMMHOqSXM-vzJUHY9LApkUvNVI3owDo_fqyhNK0/s1600-h/Mounting+the+Adapter+Plate+031.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEill1cFPeoFf6Xr4dvqBZex7ww2xz38kDlX_X99bE76oblDxNgR45GxtEFGctAIve89eLJ4gR8TdaP5eW-WpnFU2S2dKB56yW_fCLjFbMMHOqSXM-vzJUHY9LApkUvNVI3owDo_fqyhNK0/s320/Mounting+the+Adapter+Plate+031.jpg" /></a> </div><div class="separator" style="clear: both; text-align: center;">Jared double checking his measurements... </div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjiX91gwsEJRILUIrx2BXucgkKeNyrtlJfWhtfJw5EwbFc4NhjypLv8NC7caF2LqR47KV6Z37gRZvcTSopq68y9h3TVPADrLmxgkhkqzwy3ZU4FZYOZe-yYXzF7znwpeEMCgrNHPMNgQkc/s1600-h/Mounting+the+Adapter+Plate+035.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjiX91gwsEJRILUIrx2BXucgkKeNyrtlJfWhtfJw5EwbFc4NhjypLv8NC7caF2LqR47KV6Z37gRZvcTSopq68y9h3TVPADrLmxgkhkqzwy3ZU4FZYOZe-yYXzF7znwpeEMCgrNHPMNgQkc/s320/Mounting+the+Adapter+Plate+035.jpg" /></a> </div><div class="separator" style="clear: both; text-align: center;">This is what the coupler disk hub assembly from EV America looks like when dissembled. The splined hub on the left is a new Chevy S10 clutch disc that I sent them. They remove the friction material and then bolt and pin it to the their coupler disk / steel hub assembly. The splines connector in the clutch disc is need to mate with the transmission shaft.</div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQrjLHcqx9VomOFPzH2eAVXYcrBtoMaLfhGADM8EvxKeWn8K3NadwMC9j1CNkjru8tt_nO-m_BSABX00MlY7JZMFKNyuyQYyVXu4__CexlwXNHKDpveVhqYZjPCeuyXoAYLohde18x0cY/s1600-h/Mounting+the+Adapter+Plate+043.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQrjLHcqx9VomOFPzH2eAVXYcrBtoMaLfhGADM8EvxKeWn8K3NadwMC9j1CNkjru8tt_nO-m_BSABX00MlY7JZMFKNyuyQYyVXu4__CexlwXNHKDpveVhqYZjPCeuyXoAYLohde18x0cY/s320/Mounting+the+Adapter+Plate+043.jpg" /></a> </div><div class="separator" style="clear: both; text-align: center;">Realizing that we didn't want to disassemble the coupler hub assembly just yet, we put it back together, place it on the motor shaft with key, and used our previous measurements to position the hub.</div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg7hqFdMClzzqvvQdYqxm2r2bAHmNm4dgCoYzDkA5SPKpEX-2uzEu5TL3CZwPqcZ8AgLRnNB3WHg7hQgNjDfh9HD1yY8qFtLXLneNvg7AXX2LetLaKSK7Gn-hDv7qBw3jqPIjhuNBArI90/s1600-h/Mounting+the+Adapter+Plate+037.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg7hqFdMClzzqvvQdYqxm2r2bAHmNm4dgCoYzDkA5SPKpEX-2uzEu5TL3CZwPqcZ8AgLRnNB3WHg7hQgNjDfh9HD1yY8qFtLXLneNvg7AXX2LetLaKSK7Gn-hDv7qBw3jqPIjhuNBArI90/s320/Mounting+the+Adapter+Plate+037.jpg" /></a> </div><div class="separator" style="clear: both; text-align: center;">With the shaft key already in place, we put some lock-tite on the bolts and tightened the steel hub in place.</div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgl7tD5tTmd3wfsgjUmCtIdM2NQVUck0YCJEW2zzRsKqkXwO4RdatHZ6E6T8RdOXNfbnBUtfM1NgO5eACdJrK6xVmQEPjq0c1WvG0DZaoeSscwus2pcvOoIP98BpEn_vdbWTNqGgi2I0po/s1600-h/Mounting+the+Adapter+Plate+049.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgl7tD5tTmd3wfsgjUmCtIdM2NQVUck0YCJEW2zzRsKqkXwO4RdatHZ6E6T8RdOXNfbnBUtfM1NgO5eACdJrK6xVmQEPjq0c1WvG0DZaoeSscwus2pcvOoIP98BpEn_vdbWTNqGgi2I0po/s320/Mounting+the+Adapter+Plate+049.jpg" /></a> </div><div class="separator" style="clear: both; text-align: center;">Now its time to remove the clutch disc and the aluminum coupler assembly from the steel hub. This will allow us to slide the spacers and the adapter plate over the steel hub and bolt them into place. </div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgYpRvw6ZczX4AhzcUwnECNYJDWsCa2ubl4WVqahw2G38vft8y5bDz5uXs4oXMWWc6wcGWeChmX0YAaviIYRaT_3fgb5g7LTsabb3GbVzQYkV-kcdNni1TWFgB3ir1o2m9Ww_YB0gaJa8I/s1600-h/Mounting+the+Adapter+Plate+052.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgYpRvw6ZczX4AhzcUwnECNYJDWsCa2ubl4WVqahw2G38vft8y5bDz5uXs4oXMWWc6wcGWeChmX0YAaviIYRaT_3fgb5g7LTsabb3GbVzQYkV-kcdNni1TWFgB3ir1o2m9Ww_YB0gaJa8I/s320/Mounting+the+Adapter+Plate+052.jpg" /></a> </div><div class="separator" style="clear: both; text-align: center;">Double checking the steel hub bolts to make sure that they are tight. Yes, that is blue painter tape protecting my motor from damage and shavings. </div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8idSVUyVEI-J0Vp6a3yogKpuDebkuzWdwUfUxkoRFOXGGW51zvyGNw4v0rYcLLjLyUwbbEpej_UB1NJmwQUnZElAOrQpkPYO_woz4YPOxpuO92rXYB05yEr1Npsff9ywed1dVKCTLDUE/s1600-h/Mounting+the+Adapter+Plate+054.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8idSVUyVEI-J0Vp6a3yogKpuDebkuzWdwUfUxkoRFOXGGW51zvyGNw4v0rYcLLjLyUwbbEpej_UB1NJmwQUnZElAOrQpkPYO_woz4YPOxpuO92rXYB05yEr1Npsff9ywed1dVKCTLDUE/s320/Mounting+the+Adapter+Plate+054.jpg" /></a> </div><div class="separator" style="clear: both; text-align: center;">After sliding the spacers disks and the adapter plate over the steel hub we bolted it into the motor with four 3/8 by 2 3/4" grade 8 bolts, washers, lock washers, and some locktite.</div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjONMDXqhuyu1DtZ9EljPUCIwENpkTkArCKiBbFXM9lsOajCOR_RHgpoG_XxnwjJF4y75_zDfBRDz2c8a4T_l4fZsqodNdAlwkzVBi4eroXtBakFs3_LTpkGvNFBiSxwJbL1xceVAuITs0/s1600-h/Mounting+the+Adapter+Plate+062.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjONMDXqhuyu1DtZ9EljPUCIwENpkTkArCKiBbFXM9lsOajCOR_RHgpoG_XxnwjJF4y75_zDfBRDz2c8a4T_l4fZsqodNdAlwkzVBi4eroXtBakFs3_LTpkGvNFBiSxwJbL1xceVAuITs0/s320/Mounting+the+Adapter+Plate+062.jpg" /></a> </div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhtcFMEX72_PdEC2GZ_YUsHqBtFyLYM4zMGVFHVXqG8vuXH4TETgx7xX1_ynINl1yyNA2SZXQZjFvk6TR-EEZcgRC_FNpqCTBlplkIwz84pGgFe_AZwbCSgkoLKOCzMgyLTSnhnyj9r_gU/s1600-h/Mounting+the+Adapter+Plate+068.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhtcFMEX72_PdEC2GZ_YUsHqBtFyLYM4zMGVFHVXqG8vuXH4TETgx7xX1_ynINl1yyNA2SZXQZjFvk6TR-EEZcgRC_FNpqCTBlplkIwz84pGgFe_AZwbCSgkoLKOCzMgyLTSnhnyj9r_gU/s320/Mounting+the+Adapter+Plate+068.jpg" /></a> </div><div class="separator" style="clear: both; text-align: center;">Once again we reassembled the coupler disk assembly to the steel hub. Yes, more locktite...</div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEis4RHA8W3rMQPkF4Wawwag3Vn2xpBkH4rQtcFqbkYQ5XzKAa55zv8l5ORRN5xVtBh064MzdV34RIU4M2wHUg1v61SXoqIqNfST5RmcKRv_cNous05MENyHrUHjMuLTYUuB6xOmbKVnCAU/s1600-h/Mounting+the+Adapter+Plate+070.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEis4RHA8W3rMQPkF4Wawwag3Vn2xpBkH4rQtcFqbkYQ5XzKAa55zv8l5ORRN5xVtBh064MzdV34RIU4M2wHUg1v61SXoqIqNfST5RmcKRv_cNous05MENyHrUHjMuLTYUuB6xOmbKVnCAU/s320/Mounting+the+Adapter+Plate+070.jpg" /></a> </div><div class="separator" style="clear: both; text-align: center;">And finally we reattached the clutch disc with 8 bolts and locktite... </div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgo3hfRq2BBRjbWR8iHhOHgMmN8ptp45pQiE9eZE2mIxwHdgHGsGr9JuXwg4OtoCiglXZgM8vUQcZ59vCqZL_wWs4nnrCcBlT3o0h5Mx8FOni0LuhiyUBwaVuSyR26OyT5NQbCoK-1ZELw/s1600-h/Mounting+the+Adapter+Plate+074.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgo3hfRq2BBRjbWR8iHhOHgMmN8ptp45pQiE9eZE2mIxwHdgHGsGr9JuXwg4OtoCiglXZgM8vUQcZ59vCqZL_wWs4nnrCcBlT3o0h5Mx8FOni0LuhiyUBwaVuSyR26OyT5NQbCoK-1ZELw/s320/Mounting+the+Adapter+Plate+074.jpg" /></a> </div><div class="separator" style="clear: both; text-align: center;">Its beautiful! Its ready to bolt to the transmission...but that's all the time I have for today. :) </div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgaTQCrX8XGus6WmH2uGurGZwAPvjjWJ-hu5UF_EA7G4oJz-hHWgk_UCxOWKHT__OmBFUiDUD0nrz4fI2pvykmYFn95yUWmbw0JZoq2IjXebTImkfZ1EBD-zybYlZpKxdWE7oMz0Y2ONXM/s1600-h/Mounting+the+Adapter+Plate+079.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgaTQCrX8XGus6WmH2uGurGZwAPvjjWJ-hu5UF_EA7G4oJz-hHWgk_UCxOWKHT__OmBFUiDUD0nrz4fI2pvykmYFn95yUWmbw0JZoq2IjXebTImkfZ1EBD-zybYlZpKxdWE7oMz0Y2ONXM/s320/Mounting+the+Adapter+Plate+079.jpg" /></a></div><div style="text-align: center;"></div>Unknownnoreply@blogger.com3tag:blogger.com,1999:blog-8244815155369495435.post-12380751153279330752009-06-20T23:50:00.000-07:002009-06-22T23:50:55.855-07:00Build Session 23 (240 mins): Shaping the Adapter PlateI decided to hold off on the dual motor setup for now in hopes of getting this truck up and running this year.<br />
<br />
This weekend Jared, Chad, and I marked and cut the 1/2 inch adapter plate that connects the transmission bell housing to the motor adapter.<br />
<br />
We used the Rigid band saw with a 3/4 inch Lenox Bi-Metal blade and a LOT of aluminum cutting oil. The cutting was slow going but the end result was worth it. After cutting we cleaned up the edges with the grinder, wire wheel, and a little filing. During the next build session we will drill the holes and bolt the bell housing to the adapter plate.<br />
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<div style="text-align: center;">The adapter plate before we cut...</div><div style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgqIWAJZuXjx8uPHVr5eJ6jUui7MyzOPMkSfc_zyoipclXjRcpUeMXSz9lVNAzL7HDYVzkHamNUOiIEH699zNoc8mbye50q3xXSYq10lSMmYO9Ki9AK0fZDKiBY3fJM-APrtj5ClTBZFjo/s1600-h/Shaping+the+Adapter+Plate+%282%29.jpg" onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5350406379917643250" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgqIWAJZuXjx8uPHVr5eJ6jUui7MyzOPMkSfc_zyoipclXjRcpUeMXSz9lVNAzL7HDYVzkHamNUOiIEH699zNoc8mbye50q3xXSYq10lSMmYO9Ki9AK0fZDKiBY3fJM-APrtj5ClTBZFjo/s320/Shaping+the+Adapter+Plate+%282%29.jpg" style="cursor: pointer; height: 240px; width: 320px;" /></a><br />
Clamping the plate down and then tracing the bell housing...<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhqPoF8sUmfQrVvirm5CARv7xmrUmlDnFXF4TSCywbxS6_jA7F9WL4P0-Cbyq42WE58-laXL0bf9ExtaLNJ0tO7PNshTAhd65HYBypuFJ8e3Zcgi_yNuiG0NqPYYJ7BQB8B5i9f7Eq2dIY/s1600-h/Shaping+the+Adapter+Plate+%283%29.jpg" onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5350406384432427586" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhqPoF8sUmfQrVvirm5CARv7xmrUmlDnFXF4TSCywbxS6_jA7F9WL4P0-Cbyq42WE58-laXL0bf9ExtaLNJ0tO7PNshTAhd65HYBypuFJ8e3Zcgi_yNuiG0NqPYYJ7BQB8B5i9f7Eq2dIY/s320/Shaping+the+Adapter+Plate+%283%29.jpg" style="cursor: pointer; height: 240px; width: 320px;" /></a></div><div style="text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjDlazqtdCBtkP2kRTOAI0r_CpOSV_nV7Kf8uX0NRrx-62WuC_0FGtSokbhyoZHK7MbMALD4n5bFSFcbFdL2cpSkKSr7xzRaGL6a0uDIEhAuWxYM_rZnIUxDLd0phIQ7itk4-I_N2B230o/s1600-h/Shaping+the+Adapter+Plate+%286%29.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjDlazqtdCBtkP2kRTOAI0r_CpOSV_nV7Kf8uX0NRrx-62WuC_0FGtSokbhyoZHK7MbMALD4n5bFSFcbFdL2cpSkKSr7xzRaGL6a0uDIEhAuWxYM_rZnIUxDLd0phIQ7itk4-I_N2B230o/s320/Shaping+the+Adapter+Plate+%286%29.jpg" /></a> </div><div class="separator" style="clear: both; text-align: center;"> The cutting is slow...Chad keeps the blade plenty lubed with aluminum cutting oil which definitely saved the blade.</div><div class="separator" style="clear: both; text-align: center;"> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhPg5eKop7DEzQtpxNOt1U7ByPPp7ZpR-eluT8qkgAIcwtnkmWXMhGV_QvnumgUPGrcf4Fhn55fdZXt846OZz29zZ2PTyXGql_Sy8IOgCMaOKBMeGdOsfEiDKb8f5tCrWIg3WuFuZho7vU/s1600-h/Shaping+the+Adapter+Plate+%287%29.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhPg5eKop7DEzQtpxNOt1U7ByPPp7ZpR-eluT8qkgAIcwtnkmWXMhGV_QvnumgUPGrcf4Fhn55fdZXt846OZz29zZ2PTyXGql_Sy8IOgCMaOKBMeGdOsfEiDKb8f5tCrWIg3WuFuZho7vU/s320/Shaping+the+Adapter+Plate+%287%29.jpg" /></a> </div><div class="separator" style="clear: both; text-align: center;"> We used to brush to keep the oil where we wanted it...</div><div class="separator" style="clear: both; text-align: center;"> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXAK-BwWyVfU1jsD9zJ6uzNNFHg6b5D-oKgbnHHOos_brb13t-EBUmI5WaAcp-CLEEyLsVPYxoYtmdnVPuS_PkoW_xhGnn03YL06RZSHEM8CHKxLnsefKXLji8mEVUcIEGsld-Zrx-owg/s1600-h/Shaping+the+Adapter+Plate+%2811%29.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXAK-BwWyVfU1jsD9zJ6uzNNFHg6b5D-oKgbnHHOos_brb13t-EBUmI5WaAcp-CLEEyLsVPYxoYtmdnVPuS_PkoW_xhGnn03YL06RZSHEM8CHKxLnsefKXLji8mEVUcIEGsld-Zrx-owg/s320/Shaping+the+Adapter+Plate+%2811%29.jpg" /></a> </div><div class="separator" style="clear: both; text-align: center;"> Still cutting hours later...</div><div class="separator" style="clear: both; text-align: center;"> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi7WLCZKLCrXZ1y7VWOTP99ljyoDVym_1k_qAP5lgS-EZ9rhqBkgE6bbty81ij-PWIvRdQdLTfpZ7AmvLqmy2qccRDqDX7aeFlzDAHg5zofYsbBTuvXHNSARFTwA4DgSl8RpRITKOyra74/s1600-h/Shaping+the+Adapter+Plate+%2817%29.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi7WLCZKLCrXZ1y7VWOTP99ljyoDVym_1k_qAP5lgS-EZ9rhqBkgE6bbty81ij-PWIvRdQdLTfpZ7AmvLqmy2qccRDqDX7aeFlzDAHg5zofYsbBTuvXHNSARFTwA4DgSl8RpRITKOyra74/s320/Shaping+the+Adapter+Plate+%2817%29.jpg" /></a> </div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEirykLhEze23VTxU6vM9iIS-trIZ0OTaLs6eeYSRQR6bMVGNa-zT5eXPwOmXC8WTHmwEatn74MBiq3K1tkvxO6kQPtilB2R-rJ-XJ7OSdUVyPOA-MLlWwqb8wb4E_LW-4DHpEDCgfJ2T2w/s1600-h/Shaping+the+Adapter+Plate+%2818%29.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEirykLhEze23VTxU6vM9iIS-trIZ0OTaLs6eeYSRQR6bMVGNa-zT5eXPwOmXC8WTHmwEatn74MBiq3K1tkvxO6kQPtilB2R-rJ-XJ7OSdUVyPOA-MLlWwqb8wb4E_LW-4DHpEDCgfJ2T2w/s320/Shaping+the+Adapter+Plate+%2818%29.jpg" /></a> </div><div class="separator" style="clear: both; text-align: center;">Pretty good for a 3/4 inch band saw blade... </div><div class="separator" style="clear: both; text-align: center;"> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgFzWB0o6686M-DHmooKsXMYtG-FZMojt0klSWW9jl2qiB6fmyUISAF3POa3THdv8DBuV-KY8at68bgc5CqD3Ze4zX4Q99zunHIKWBoL8INTR1X-eS6Jud_Ws5NafcUq__c-L6CgXJ5kzU/s1600-h/Shaping+the+Adapter+Plate+%2820%29.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgFzWB0o6686M-DHmooKsXMYtG-FZMojt0klSWW9jl2qiB6fmyUISAF3POa3THdv8DBuV-KY8at68bgc5CqD3Ze4zX4Q99zunHIKWBoL8INTR1X-eS6Jud_Ws5NafcUq__c-L6CgXJ5kzU/s320/Shaping+the+Adapter+Plate+%2820%29.jpg" /></a> </div><div class="separator" style="clear: both; text-align: center;">I'm grinding down the rough cuts... </div><div class="separator" style="clear: both; text-align: center;"> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgmPNasBJ8EOPWAFxqMUtMk694jSCMzkVQe0inW3Hv9JkguLVHbqIYNdXWCN9OgMqkkTSns_4jztlgTQXmL84bgMsoRaPbTDBsvdH6-mDJrvatXI-hjNmBmNu50lUW9gzqkAKyVV0ctYCU/s1600-h/Shaping+the+Adapter+Plate+%2826%29.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgmPNasBJ8EOPWAFxqMUtMk694jSCMzkVQe0inW3Hv9JkguLVHbqIYNdXWCN9OgMqkkTSns_4jztlgTQXmL84bgMsoRaPbTDBsvdH6-mDJrvatXI-hjNmBmNu50lUW9gzqkAKyVV0ctYCU/s320/Shaping+the+Adapter+Plate+%2826%29.jpg" /></a> </div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEghM7IWswbZntOKrNTmS5P3ryizmFs1svx3YcKmzKHjxXQjubcYsOcVdyyKNX2iO1rXFxV8SigXDgCFilcMkDgNVl3_FqgqjmDXKyJN1ZaWbR6OBPuiOu__wCXOUxXz9oa1b8loXaJwP0k/s1600-h/Shaping+the+Adapter+Plate+%2829%29.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEghM7IWswbZntOKrNTmS5P3ryizmFs1svx3YcKmzKHjxXQjubcYsOcVdyyKNX2iO1rXFxV8SigXDgCFilcMkDgNVl3_FqgqjmDXKyJN1ZaWbR6OBPuiOu__wCXOUxXz9oa1b8loXaJwP0k/s320/Shaping+the+Adapter+Plate+%2829%29.jpg" /></a> </div><div class="separator" style="clear: both; text-align: center;">Chad decided to hand file a bit. </div><div class="separator" style="clear: both; text-align: center;"> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhH0n41PVt3_Eu_zFlnVPBQCzSE8NGkNwB7pAW-ml1dY7ImxAhZ3b6mmGpNUg4wme01FW8oD1pjn-SUbCLlBVyR7g2TtL1pnlshIfuIHCxyxOOx-mi-uGt5QtUAS6SwKQwTVmp0CxdzdaM/s1600-h/Shaping+the+Adapter+Plate+%2849%29.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhH0n41PVt3_Eu_zFlnVPBQCzSE8NGkNwB7pAW-ml1dY7ImxAhZ3b6mmGpNUg4wme01FW8oD1pjn-SUbCLlBVyR7g2TtL1pnlshIfuIHCxyxOOx-mi-uGt5QtUAS6SwKQwTVmp0CxdzdaM/s320/Shaping+the+Adapter+Plate+%2849%29.jpg" /></a> </div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjcD8g7Zc3GANrzZf_t1RzjiRiNHE1QdeOnBH1rS2OPXEh3EwSPWe-n49Q_RDR7XB9prRSbA5ov-fu-qQIZ-8RGkiQOFytprTjwDSYPMOR88dC0OW5x8kPXkNhw1Nlx0RSHMGpiZZ7W4Ek/s1600-h/Shaping+the+Adapter+Plate+%2851%29.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjcD8g7Zc3GANrzZf_t1RzjiRiNHE1QdeOnBH1rS2OPXEh3EwSPWe-n49Q_RDR7XB9prRSbA5ov-fu-qQIZ-8RGkiQOFytprTjwDSYPMOR88dC0OW5x8kPXkNhw1Nlx0RSHMGpiZZ7W4Ek/s320/Shaping+the+Adapter+Plate+%2851%29.jpg" /></a> </div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;">Perfect fit...I like it. Its ready for drilling during the next build session. </div><div class="separator" style="clear: both; text-align: center;"> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCLFplNtsgn9dTqKIKEFfoIcko89XrD_-squAoWOgK0d1DlUOCEO0mgomh5O0EXf0ZFiAhdo3MOdSDyyPJ7oEDKfi7tg3WRuv5Y8EDuyl7S9wk9lWOmM0o8_Wb_zQ6Nxb3fodWlvvPRVM/s1600-h/Shaping+the+Adapter+Plate+%2853%29.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCLFplNtsgn9dTqKIKEFfoIcko89XrD_-squAoWOgK0d1DlUOCEO0mgomh5O0EXf0ZFiAhdo3MOdSDyyPJ7oEDKfi7tg3WRuv5Y8EDuyl7S9wk9lWOmM0o8_Wb_zQ6Nxb3fodWlvvPRVM/s320/Shaping+the+Adapter+Plate+%2853%29.jpg" /></a></div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"></div><div style="text-align: center;"></div>Unknownnoreply@blogger.com4tag:blogger.com,1999:blog-8244815155369495435.post-56623033810038048262009-06-12T21:44:00.000-07:002009-06-22T23:22:40.567-07:00Build Session 22 (60 mins): Another Coat of POR-15Jared and I added a coat of POR-15 Chassis Coat black on top of the epoxy paint. The Chassis Coat provides UV protection (fade resistance) on top of the rust preventing epoxy coat.<br /><br /><div style="text-align: center;"><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjzUzirfmDSYIOj3QufZSYcQE3e-zlYWs_B_5Djw5Z9AZo5SIk4LziPPACTSaj2ZuQEASbLhlYnFqhujdcQTfqpFYGmfUKKLmjzJZ88b2RYnf6gg6whETtBWrU88VXk5sm1OiJvWuKwBSo/s1600-h/Chevy+S-10+Epoxy+Painting+%2830%29.jpg"><img style="cursor: pointer; width: 320px; height: 240px;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjzUzirfmDSYIOj3QufZSYcQE3e-zlYWs_B_5Djw5Z9AZo5SIk4LziPPACTSaj2ZuQEASbLhlYnFqhujdcQTfqpFYGmfUKKLmjzJZ88b2RYnf6gg6whETtBWrU88VXk5sm1OiJvWuKwBSo/s320/Chevy+S-10+Epoxy+Painting+%2830%29.jpg" alt="" id="BLOGGER_PHOTO_ID_5350404555271059394" border="0" /></a><br /></div>Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-8244815155369495435.post-58684599277213413482009-06-05T23:18:00.000-07:002009-06-22T23:20:22.136-07:00Build Session 21 (180 mins): Epoxy Painted Battery Racks and FrameThis weekend Jared, Chad, and I had a productive painting session. In a couple of hours we managed to finish the welding on the rear battery racks. Then we painted the rear battery racks, rear differential, and frame with POR-15 Epoxy paint which should keep them from rusting.<br /><br /><br /><div style="text-align: center;">Jared and my welding helmets. </div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj7a8EZ010XqrotCul4-hSqMJNfT2YFvmTwv5qJbXEMkhBsi70XEQLlAoF60MBr1MhfU-coo2RdrlldqZSgZzLgkFQCPgtr-jLFuyTMcxCg2zqOC7EaMH6IEuFu7avJlkYwBbsGj4eL-zg/s1600-h/Chevy+S-10+Epoxy+Painting+%2842%29.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj7a8EZ010XqrotCul4-hSqMJNfT2YFvmTwv5qJbXEMkhBsi70XEQLlAoF60MBr1MhfU-coo2RdrlldqZSgZzLgkFQCPgtr-jLFuyTMcxCg2zqOC7EaMH6IEuFu7avJlkYwBbsGj4eL-zg/s320/Chevy+S-10+Epoxy+Painting+%2842%29.jpg" border="0" /></a></div><div style="text-align: center;"> Jared and Chad painting. Chad is a good friend of ours. He just graduated from High School, is an invaluable robotics club member on the team that we mentored and is a skilled machinist. Not bad for a teenager!</div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjifJx3E84gijIfA1YCCvQAedf7oYi9IxVXRSPf5BDcUfvP5jvbngUhlqqFCbENNvAL1YJttYSBEom4hXfkIYjwgt9Y-v99LOYkRosz8V3VleL5bZEzfgeAQVBak5vlWNsI6e0YGWcTL30/s1600-h/Chevy+S-10+Epoxy+Painting+%282%29.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjifJx3E84gijIfA1YCCvQAedf7oYi9IxVXRSPf5BDcUfvP5jvbngUhlqqFCbENNvAL1YJttYSBEom4hXfkIYjwgt9Y-v99LOYkRosz8V3VleL5bZEzfgeAQVBak5vlWNsI6e0YGWcTL30/s320/Chevy+S-10+Epoxy+Painting+%282%29.jpg" border="0" /></a></div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh3FUdHSnKTt73XHF7bNzO8Tuo8Q5EOxqokdDq-DPeyZ0dz0sNVqyqfoMaw0rA4DBSJa8ov2HkKEXNmiYNse_iFKgOgWtw_pKDHVprhTHKSjONfJdroO4_f_V_Oa5ifBFU7WtXJdSLUemw/s1600-h/Chevy+S-10+Epoxy+Painting+%286%29.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh3FUdHSnKTt73XHF7bNzO8Tuo8Q5EOxqokdDq-DPeyZ0dz0sNVqyqfoMaw0rA4DBSJa8ov2HkKEXNmiYNse_iFKgOgWtw_pKDHVprhTHKSjONfJdroO4_f_V_Oa5ifBFU7WtXJdSLUemw/s320/Chevy+S-10+Epoxy+Painting+%286%29.jpg" border="0" /></a></div><div style="text-align: center;">Starting from the inside and working our way out...</div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjOZWNoKgjKEmCU2IQ-ZIAJysHtlbhAzoGh2QtmiedQsNvTNPiS-mr3qKmlir3PKUkKHeF0v9Ba_m3dWWmBT58wwf207jRdmrsfakqj8ZurDWLQ0qehQdjqAy_2ei4bp-r3eeBjEpkY_hA/s1600-h/Chevy+S-10+Epoxy+Painting+%285%29.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjOZWNoKgjKEmCU2IQ-ZIAJysHtlbhAzoGh2QtmiedQsNvTNPiS-mr3qKmlir3PKUkKHeF0v9Ba_m3dWWmBT58wwf207jRdmrsfakqj8ZurDWLQ0qehQdjqAy_2ei4bp-r3eeBjEpkY_hA/s320/Chevy+S-10+Epoxy+Painting+%285%29.jpg" border="0" /></a> </div><div class="separator" style="clear: both; text-align: center;"> Remember how many months ago we spent a whole day prepping the frame with scrub brushes and the pressure washer...I think it was about a year ago. Wow, time fly's.</div><div class="separator" style="clear: both; text-align: center;"> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgasaSiWk5UZOwRHqkjccW-seni6DqUnSAtSf7GKU6Qy4aASRMfj-ZtO2KMiVie2QLcD60opysmjb08mQIttbpPYl2LohJj-C3LirPNgALW0QPdBDzFwpXJjmqRcjOB8yS3E06Ugs-PXJQ/s1600-h/Chevy+S-10+Epoxy+Painting+%2810%29.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgasaSiWk5UZOwRHqkjccW-seni6DqUnSAtSf7GKU6Qy4aASRMfj-ZtO2KMiVie2QLcD60opysmjb08mQIttbpPYl2LohJj-C3LirPNgALW0QPdBDzFwpXJjmqRcjOB8yS3E06Ugs-PXJQ/s320/Chevy+S-10+Epoxy+Painting+%2810%29.jpg" border="0" /></a> </div><div class="separator" style="clear: both; text-align: center;">I even painted the frame underneath after laying out plastic on the driveway an taping plastic around the cab. </div><div class="separator" style="clear: both; text-align: center;"> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEge9pLbC5uzERQeMT-ieEA1yTh_E_U263-k1I8JgrxqQarToJSQkakZDvdhDPVNlKVWGlnlML8yBtGjE1nL65stSMOTnBSz1EMxqjxxpBO68fZH5JmQYi0HzH9i5UM9RJhmzfDATcjfBy0/s1600-h/Chevy+S-10+Epoxy+Painting+%2815%29.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEge9pLbC5uzERQeMT-ieEA1yTh_E_U263-k1I8JgrxqQarToJSQkakZDvdhDPVNlKVWGlnlML8yBtGjE1nL65stSMOTnBSz1EMxqjxxpBO68fZH5JmQYi0HzH9i5UM9RJhmzfDATcjfBy0/s320/Chevy+S-10+Epoxy+Painting+%2815%29.jpg" border="0" /></a> </div><div class="separator" style="clear: both; text-align: center;"> The epoxy paint goes a long ways and looks great.</div><div class="separator" style="clear: both; text-align: center;"> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEitn3BUYKD14jhXzSz5ROMcGPR5ExyviV4jpi2QREXflOteWzP-JIAHx7spauyDT9m9LaXxf3jjFOBIuwOO4AqvhgMZndrsoTM3nmUOM1F0LYFOK0KJNncCUYub73hOsdmquIT_3uWCEWk/s1600-h/Chevy+S-10+Epoxy+Painting+%2817%29.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEitn3BUYKD14jhXzSz5ROMcGPR5ExyviV4jpi2QREXflOteWzP-JIAHx7spauyDT9m9LaXxf3jjFOBIuwOO4AqvhgMZndrsoTM3nmUOM1F0LYFOK0KJNncCUYub73hOsdmquIT_3uWCEWk/s320/Chevy+S-10+Epoxy+Painting+%2817%29.jpg" border="0" /></a> </div><div class="separator" style="clear: both; text-align: center;"> Nice...</div><div class="separator" style="clear: both; text-align: center;"> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjPESw3lur7ICUqOlSVwV-Crhq0-VyMjDZw-Rq1ujbJVDzG7CnMc507YGJsjIHzNmFYSNtYwKcuMIEAKsjD7sYCPM-sALF2_y0T22wicS3MsSxuRKvt-Ou0pqSWwRMXTgnpd5cAacuTEoY/s1600-h/Chevy+S-10+Epoxy+Painting+%2829%29.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjPESw3lur7ICUqOlSVwV-Crhq0-VyMjDZw-Rq1ujbJVDzG7CnMc507YGJsjIHzNmFYSNtYwKcuMIEAKsjD7sYCPM-sALF2_y0T22wicS3MsSxuRKvt-Ou0pqSWwRMXTgnpd5cAacuTEoY/s320/Chevy+S-10+Epoxy+Painting+%2829%29.jpg" border="0" /></a> </div><div class="separator" style="clear: both; text-align: center;"> It looks amazing!</div><div class="separator" style="clear: both; text-align: center;"> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEirxW2rgcG9ktfKqSM60kO0LvPgGLftRvi8XwUq3R2342mLgDUQGzEuh9Ny_r2ikvRVnS1L8IwZkcl6W9RJo45bFtBQfDAnEH7UhXvL_qtb34KcvMEKwQCURF3Z4OsvODG-bIktewLOUhI/s1600-h/Chevy+S-10+Epoxy+Painting+%2826%29.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEirxW2rgcG9ktfKqSM60kO0LvPgGLftRvi8XwUq3R2342mLgDUQGzEuh9Ny_r2ikvRVnS1L8IwZkcl6W9RJo45bFtBQfDAnEH7UhXvL_qtb34KcvMEKwQCURF3Z4OsvODG-bIktewLOUhI/s320/Chevy+S-10+Epoxy+Painting+%2826%29.jpg" border="0" /></a></div><div class="separator" style="clear: both; text-align: center;">Chad got some POR-15 epoxy on himself...It should wear off in a few weeks. Sorry Chad. :) </div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjBjOQCU2zdZqjFupMURjVJZR7tQAcAhCproS2Wi1Ci6q4LVRxeXjnStyiKs9SCw2TDEb7yCDSV17nR6ZdVGdKWW2OwnhwR1HawxEVvtC90A7Xh_B5lR7y1hfp26x20CvKjExWR6qX8-IA/s1600-h/Chevy+S-10+Epoxy+Painting+%2832%29.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjBjOQCU2zdZqjFupMURjVJZR7tQAcAhCproS2Wi1Ci6q4LVRxeXjnStyiKs9SCw2TDEb7yCDSV17nR6ZdVGdKWW2OwnhwR1HawxEVvtC90A7Xh_B5lR7y1hfp26x20CvKjExWR6qX8-IA/s320/Chevy+S-10+Epoxy+Painting+%2832%29.jpg" border="0" /></a> </div><div class="separator" style="clear: both; text-align: center;"></div><div style="text-align: center;"></div>Unknownnoreply@blogger.com2tag:blogger.com,1999:blog-8244815155369495435.post-49493499368594560552009-06-03T22:46:00.000-07:002009-06-22T22:23:31.197-07:00Zilla Z2K Controller Finally Arrived!Yes, it has been over six months since I have posted! I have been extremely busy with work and mentoring a high school robotics team. School is out and robotics is over for now. Work is still extremely busy but several EV discussions with my good friend Jared has helped motivate me to spend a little bit of time each week on the project...regardless of work deadlines. I hope to continue making progress and posting the results on a more regular basis.<br /><br />But that's not the purpose of this post. If you haven't already guess from the title of this post...drum roll please...yes, after almost eight months of waiting THE ZILLA HAS ARRIVED!!! It makes me happy. :)<br /><br /><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjqzSA9bfgyIIbp_3OIwmr0IMFr837bTLYQ_vaUz1uKgJ3YsiocJF3cnZV2XzvYBXrh_1pl0fHvT_5E6j4P-8pldhyLmACqLG3puKPfv77bcFcaofIVB6KsFlCsxJLL-swZ993I3nO9yIg/s1600-h/IMG_1298.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjqzSA9bfgyIIbp_3OIwmr0IMFr837bTLYQ_vaUz1uKgJ3YsiocJF3cnZV2XzvYBXrh_1pl0fHvT_5E6j4P-8pldhyLmACqLG3puKPfv77bcFcaofIVB6KsFlCsxJLL-swZ993I3nO9yIg/s320/IMG_1298.JPG" border="0" /></a> </div><div class="separator" style="clear: both; text-align: center;"> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjayL6o3kBQLereR_fATt4v43vhK1TOeewPW-LO2HvFSLyXhmAnFgPZVzIx2ZYiY1GNrEtJEIZMkBXGxbmEsD_CCSjumz0U7qPicOCHT2FixgLvtQ8SrYN6rXwwZUujOLt9Z-oDrvyO9Zk/s1600-h/IMG_1299.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjayL6o3kBQLereR_fATt4v43vhK1TOeewPW-LO2HvFSLyXhmAnFgPZVzIx2ZYiY1GNrEtJEIZMkBXGxbmEsD_CCSjumz0U7qPicOCHT2FixgLvtQ8SrYN6rXwwZUujOLt9Z-oDrvyO9Zk/s320/IMG_1299.JPG" border="0" /></a> </div><div class="separator" style="clear: both; text-align: center;"> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEinnatnZiWuIh4lwrwLsyI8QrIiX3zOgNZaFVjg3vqgfN8_CwA62lGbFCjwWJ0i2NjjgJSDJQYXNhxfRbfvH9Raz0d9jlayibshqfvDoZANiaeG91hrcaLNTzvtasnRvxgaAj5QaThl20c/s1600-h/IMG_1301.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEinnatnZiWuIh4lwrwLsyI8QrIiX3zOgNZaFVjg3vqgfN8_CwA62lGbFCjwWJ0i2NjjgJSDJQYXNhxfRbfvH9Raz0d9jlayibshqfvDoZANiaeG91hrcaLNTzvtasnRvxgaAj5QaThl20c/s320/IMG_1301.JPG" border="0" /></a> </div><div class="separator" style="clear: both; text-align: center;"> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjx6Zah1z7FdLjsBnXknBhGiY693RXbqQB5Hjs5n0Wj7X5jUBlYQMw5ptawzubkWMJjn_4vTHqF37n1MfHPCapC3dRRQ4MiWaoNYH8dTEBv9tv9jdd61eaSaKa8-z5_tr9T0mJNMNHUZ6g/s1600-h/IMG_1302.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjx6Zah1z7FdLjsBnXknBhGiY693RXbqQB5Hjs5n0Wj7X5jUBlYQMw5ptawzubkWMJjn_4vTHqF37n1MfHPCapC3dRRQ4MiWaoNYH8dTEBv9tv9jdd61eaSaKa8-z5_tr9T0mJNMNHUZ6g/s320/IMG_1302.JPG" border="0" /></a> </div><div class="separator" style="clear: both; text-align: center;"></div>Unknownnoreply@blogger.com4tag:blogger.com,1999:blog-8244815155369495435.post-52580760303816075032008-11-01T20:08:00.000-07:002008-11-01T20:27:45.136-07:00Battery Box Layout Diagram<div class="separator" style="clear: both; text-align: left;">I'm still busy with family activities, at work, and with various projects as a mentor of the Tahoma Robotics Club so I currently have very little time to work on this project. However, the good new is that my batteries are on order! Specifically, 50 ThunderSky 160 amp hour batteries. Initially, I plan to use 48 of them at 3.2 volts nominal each for a total of 153.6 total volts. I have been working with <a href="http://www.manzanitamicro.com/">Manzanita Micro</a> and they have agreed to order the batteries for me. My original plan was to order the TS batteries direct from China but I dreaded the hassle of getting them through customs.  Manzanita Micro has experience ording these cells as they use them in their prius hybrid kits. So, I sent them a check and now I wait.  The lithium batteries may arrive this year although it won't slow me down any if they don't since my Zilla controller won't be ready until May or June. And so I must be patient...</div><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: left;">I created a diagram for those of you who are interested in some of the dimensions and layout of the battery boxes. The 48 ThunderSky cells will completely fill the forward twin battery boxes under the lift bed and a little over half of the rear battery box, leaving me some room for expansion in the future. With 48 of the 160 amp hour cells the total traction pack will contain over 24,000 kwh.  I estimate that this will provide me with a range of 100 plus miles at my average daily driving speeds. But only time will tell...</div><div><br /></div><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: left;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi_KFgfrVB8VlIcwo1SEXM-c2ilacwUVhAAbRGroQBguM01dhIXBT92hFHHc1ES2SzZLTF19I8JN28sufEnshgN9EtzqIR5GK4buSY8FdZXBR40B_ArYlWO6lJBPrT3U1_Wk2d_0w7A5No/s1600-h/Battery+Box+Layout.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhNgUsyK6Ujp98m7efuCERB-_owfpGvQN-e34xuJJdiL_brJj1QXd0Sb1iMlqOZBEZ_RDAF0FJ5BRb5FlmF1MOsDxv5pIa8Ft68sZ04nJpw9VLF5ofrWGNZWUXMGA1jtKFrtT8tdkosRI0/s320-r/Battery+Box+Layout.png" /></a></div><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: left;">Notice the red motors in the diagram with not tranmission. I have done a lot of research lately on the possiblity of building a direct drive system. Which basically means connecting the motor or motors directly to the drive line and eliminating the transmission completely. Many people that I have contacted say it can't or shouldn't be done while others seem to disagree. John (coworker and former race car builder/driver) and I have completed many calculations on this subject and have determined that two WarP / Impulse 9 inch motors connect in series will provide ample torque even on hills at slow speeds when controlled by my Zilla and its<a href="http://cafeelectric.com/zilla.php?zenAdminID=74843299a81299efa3d61314338bea89&zenAdminID=74843299a81299efa3d61314338bea89&zenAdminID=74843299a81299efa3d61314338bea89&zenAdminID=74843299a81299efa3d61314338bea89"> parallel / series</a> capabilities. So, I am tentatively planning to move forward with this plan and may put an order in for a couple of Impulse 9 motors at the end of this year. I'll keep you posted...</div><div class="separator" style="clear: both; text-align: left;"><br /></div><div style="text-align: left;"></div>Unknownnoreply@blogger.com5tag:blogger.com,1999:blog-8244815155369495435.post-40450328441346902502008-10-18T23:00:00.000-07:002008-10-19T12:26:48.634-07:00Build Session 20 (60 mins): Started Prepping Battery Racks for Paint<div style="text-align: left;">Finding time to work on my truck lately still seems to be few and far between...</div><div style="text-align: left;">However, I was able to fabricate and weld in a final battery rack support member between the two forward battery racks.</div><div style="text-align: left;"></div><div class="separator" style="clear: both; text-align: left;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhttvp8yMwphFudnAjhCgK53BbinZrU2GMlEr-wn2JtdL0UxslilVRouZs31V8EAfbEIx9uqb0Y7aB4tNUVjpYIsX5FnitOxfwy0j_BmkXchdKZ6UTDrVQ1lv49mAO_IIlnOqDineqjSJ0/s1600-h/Chevy+S10+Forward+Rear+Battery+Rack+004.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgw2m5_SLW782dxXnNcAnGvl1ndPVqyacJpdCKfpJFDchBGStez9NvHRKadevcIbPOB_HwwdLagoHU9Z7xsMVuhdb65hrAgxzSgmk3fBdY0k7HGQ3ok9DZip6_WUZxJWorSFEc2tlJRs1g/s320-r/Chevy+S10+Forward+Rear+Battery+Rack+004.jpg" /></a></div><div class="separator" style="clear: both; text-align: left;"></div><div class="separator" style="clear: both; text-align: left;">I plan to epoxy coat (paint) the entire frame with <a href="http://www.por15.com/">POR15</a> rust protector and chassis coat. I'm currently prepping the frame by removing the rust, dirt, etc...</div><div class="separator" style="clear: both; text-align: left;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiy42QQlgDmug7hSulk8HtN2f8Tdu_dZVXb8nBPZdR7vCw52AGxFy22LaMg-DekPUQ8o-pNBltpYCV0wI2TNDnqkPp5fzcRCUm8zqh6HimYvyvOaHnPkxZwOJ8WltjacLqrIRpdNOhIBTQ/s1600-h/Chevy+S10+Forward+Rear+Battery+Rack+003.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQj5PsJcIjdDgcNSMfHtNI5RR4JDX49TxkvS55iwOGg8NKvzYGUbx5zq1_TcCImnLyLa67BAmLq1RYNAMDUp3uH-M3GAemPR-aAt_Ufuffrbhaibd5EN7OH0lo4a-YtpTVRToXtCng_2Q/s320-r/Chevy+S10+Forward+Rear+Battery+Rack+003.jpg" /></a></div><div class="separator" style="clear: both; text-align: left;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjnDSdhwLGuypK2HTc4k9wvMPczxNpJpHWwzbVj-HU7Yw8W3I3LG9weqWz-sxomZVmgYdQMhmKiPf5Smc4WxlP6EEN6u71ygkbX0BlDTIriGC23c75UnNyX5XVLZzdihDw0WAOcetZzG0o/s1600-h/Chevy+S10+Forward+Rear+Battery+Rack+006.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi_5MFXWdUXifwumriYX92a4w7ISGQQ4RQDIzF6nvK4Fs3X6x90GSAhD4H_dH8qKp8IW3G8Xb6P06vmRWp30d9stzzgIf_Frb0Q1lr4RDjGYDLndZmQ5HLotZz7ZlVVB-ChjGtU9-myyzw/s320-r/Chevy+S10+Forward+Rear+Battery+Rack+006.jpg" /></a></div><div class="separator" style="clear: both; text-align: left;"></div><div class="separator" style="clear: both; text-align: left;">I'm pretty busy of the next few weeks but I hope to complete the prep work and rack painting by mid November.</div><div class="separator" style="clear: both; text-align: left;"></div><div style="text-align: left;"></div><div style="text-align: left;"></div>Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-8244815155369495435.post-25592715815189752402008-10-15T23:43:00.000-07:002008-10-16T07:53:32.893-07:00Ordered a Zilla Z2K Controller Today!<div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4iD4n-Z4H2CGB36vu9IeoRE1FCTnzlvEqqvPzF4u4kRMDTuFpRM1Di1SmYdCPp0yKnopQpCxODzG9-rknXz4p61m6iqZyn7R_hJbRMxk1S3pngcvDyQc4CAnWT7npXbpg_l5K0l7MlGY/s1600-h/z2k.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhZ3eGMZq2XRGa8JqqAtbn9idvk3uAXHRLvfDpsadQmaODjOIB9CLgpRdhpzWFXj94EYi7yEloczPw2gP2fCvjb5W8c2spdPK9A2XoP-z2lGjvc8_Y20Fzw1imcFng8wR8G3fYRwmHxXQ4/s320-r/z2k.jpg" /></a></div><br />
<a href="http://cafeelectric.com/zilla.php?zenAdminID=74843299a81299efa3d61314338bea89&zenAdminID=74843299a81299efa3d61314338bea89&zenAdminID=74843299a81299efa3d61314338bea89&zenAdminID=74843299a81299efa3d61314338bea89">Zilla Controller</a><br />
</div><div>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.<br />
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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.<br />
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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.<br />
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Hmmm.... Now I need a <a href="http://www.go-ev.com/TransWarP.html#TransWarP_11">TransWarp 11</a> motor with direct drive shaft. Then I can eliminate my transmission altogether and really make this truck peppy!</div><div></div>Unknownnoreply@blogger.com1tag:blogger.com,1999:blog-8244815155369495435.post-3091606763957590112008-10-04T23:29:00.000-07:002008-10-05T01:07:52.114-07:00Build Session 19 (180 mins): Forward Battery Rack Complete, Welding Supports<div class="separator" style="clear: both; text-align: left;">I completed the battery racks today!</div><div class="separator" style="clear: both; text-align: left;"></div><div class="separator" style="clear: both; text-align: left;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhh-jE0YdgoISGhQPd6N6IzMyv_TNcIuCps_BZ0GMVNudxtpWtJAvKDWiCeSNO8e2rF6S80235TSwIxKDoH10Mfsh5hRa7fvip0xB1fIs-0z10Iv23mAb8A5lU8HLdSAFNnuquYx999K5s/s1600-h/Chevy+S10+Forward+Rear+Battery+Rack+001.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEij-a5-wNm9rrXry1_VvzXGnu8jBflr09nWDGj6_u1P3QCcGmfNHEo_V2hrxIAFZ29gmfXHR0eRXziQvU94kjOiOUq8q9J8uI0byCl401yOSGoyQUTutoMVkITR6QJQdvgTDW6G9_Qyt1U/s320-r/Chevy+S10+Forward+Rear+Battery+Rack+001.jpg" /></a></div><div class="separator" style="clear: both; text-align: left;"></div><div style="text-align: left;">Welded the six supports in place...</div><div class="separator" style="clear: both; text-align: left;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjaDDkFD2s_mMgxVSMLFGf_votQsDGUYcHvt-N-bgow3D4KB92sb59NBgGYU8vmeJ0PFUjD1uxotnQclEXCRBJx0znULx7LafMx4LP_wiAX4nRf_kuKJYzokS6mM6HnW2RykOlPoR_0HQg/s1600-h/Chevy+S10+Forward+Rear+Battery+Rack+008.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj3Y4XF3XLgNRVuJgoVf2DCclmZMWSu4NYTcWasb4AJfjQ0reshGSNPwRDJwXGmnvLMOKlweHg1HufWdgyLWDxOEq_PPDQ86uLXn4jIsh-HR7V4jXXD02f3StuCpOU72KGwHav1KbbOJx0/s320-r/Chevy+S10+Forward+Rear+Battery+Rack+008.jpg" /></a></div><div class="separator" style="clear: both; text-align: left;"></div><div class="separator" style="clear: both; text-align: center;"></div><div style="text-align: left;">The completed forward battery racks...</div><div style="text-align: left;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjxfllHO-u8n5SjVOPEipHd1eQaBbWPoSQfBucILN9QDQtsJiH-6kPL9bkeK-atxhE-WIiknChK9BfkC50aiclrOkP0cYPCJ8S4derO7mJhtKMc0bNzyxbRZnQie9Hy-rZO5COw4J7QMRY/s1600-h/Chevy+S10+Forward+Rear+Battery+Rack+006.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><span class="Apple-style-span" style="color: black;"></span></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjxfllHO-u8n5SjVOPEipHd1eQaBbWPoSQfBucILN9QDQtsJiH-6kPL9bkeK-atxhE-WIiknChK9BfkC50aiclrOkP0cYPCJ8S4derO7mJhtKMc0bNzyxbRZnQie9Hy-rZO5COw4J7QMRY/s1600-h/Chevy+S10+Forward+Rear+Battery+Rack+006.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiItcZQXu0SSgEIsjlrelfL6o5V9iXj4c_VgJSIqT6x1BYbqpRClxZZVeeb-bY0LoB_KspbeGNEs4yRf9sBOb282L7gNxAnc0TDDjnSPdrFlnVikj02pT4XjzVH1zUoH4zlL64qsEeJwwM/s320-r/Chevy+S10+Forward+Rear+Battery+Rack+006.jpg" /></a><br />
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<div class="separator" style="clear: both; text-align: left;"></div><div class="separator" style="clear: both; text-align: center;"></div><div style="text-align: left;">The rear and forward battery racks...</div><div style="text-align: left;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgnUaBA7eY1h_7ml4AaRFEx-bndu-BRDprAvCq22Yl4IIYrDyapX5N4hArrBfEePFtDf4Vv1VYiNc8NN2r7id4kCZuW93sPqgCDbypNpxvncVFyMt860irYRQZLoV9GZvSXelM4C9h6dkc/s1600-h/Chevy+S10+Forward+Rear+Battery+Rack+007.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><span class="Apple-style-span" style="color: black;"></span></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgnUaBA7eY1h_7ml4AaRFEx-bndu-BRDprAvCq22Yl4IIYrDyapX5N4hArrBfEePFtDf4Vv1VYiNc8NN2r7id4kCZuW93sPqgCDbypNpxvncVFyMt860irYRQZLoV9GZvSXelM4C9h6dkc/s1600-h/Chevy+S10+Forward+Rear+Battery+Rack+007.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEghnipKp4z8u969JLW2gr2qMiS6GEYiACi4gJvpcdC1X4AUpOnW65qlLMTSMgxIq-uYWe4pqkSuW1uBCuqqtNjhUlUlDrIDgYEjFu4LSpUhhydUB7pg-p-_57XmcLAypw3pYnzemIgyRCg/s320-r/Chevy+S10+Forward+Rear+Battery+Rack+007.jpg" /></a><br />
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<div style="text-align: left;"></div>Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-8244815155369495435.post-32219568722179959532008-10-03T23:08:00.000-07:002008-10-05T15:35:09.823-07:00LiFePO4 Thundersky Batteries and a PFC50B Manzanita Micro ChargerI 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<a href="http://www.manzanitamicro.com/"> Manzanita Micro</a> 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.<br /><br />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).<div><br /></div><div><br /></div>Unknownnoreply@blogger.com2tag:blogger.com,1999:blog-8244815155369495435.post-4675106951453300412008-09-27T21:20:00.000-07:002008-09-28T21:47:22.100-07:00Build Session 18 (180 mins): Forward Battery Rack, Fabricating Supports<div class="separator" style="clear: both; text-align: left;">Yes, I finally finished the rear battery rack and am now working to complete the forward battery rack. When complete the rack will hold 32 160ah thundersky batteries or 8 Lead Acid batteries.</div><div class="separator" style="clear: both; text-align: left;"></div><div class="separator" style="clear: both; text-align: left;">First I cut the 4 lengths of 2 inch flat bar for the four U supports...</div><div class="separator" style="clear: both; text-align: left;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEitm1qn9dvg6fO0DWqS2VTewNfK-_CQKjnc-R2Mzouyuz8VEpHFvJTZo2di7Euy6HHyhdWF2SI61xdm-ABWvzCQAYOCU9VZCf8R4xDRstPKg-TVbsg-XbNRW2IB8dtQlq6Kxb4CyGBrkIE/s1600-h/Chevy+S10+Forward+Rear+Battery+Rack+003.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg843wrrTKjqwykNoFiANsKi9xJPIPq1bf0iyyiM5DyuWgdqxyISBXGLdqh4CsCrYy7PTj72SNMAQMs_j-S1Qpzy4dDyHALIWTU9gMyYVo7WMyWaNwNsG7jNXOC2olitNEPRhOlg_9xZBw/s320-r/Chevy+S10+Forward+Rear+Battery+Rack+003.jpg" /></a></div><div class="separator" style="clear: both; text-align: left;"></div><div class="separator" style="clear: both; text-align: center;"></div><div style="text-align: left;">Then I bent the four pieces into U shapes using the torch and a few clamps...</div><div style="text-align: left;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjTh1Hsq8TF47jeSpLcHzWkMEqP5oHZRUSMHqr5MOCFHdrXyEst9A8EkU76X7KMCnpKcQpmYCsy0IVWcOVnMNauZQfr4iJVjmmciOUNxBL5DXAhNApgPkqlMcZwEEspIyuQu0ruo5gfbjQ/s1600-h/Chevy+S10+Forward+Rear+Battery+Rack+013.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><span class="Apple-style-span" style="color: black;"></span></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjTh1Hsq8TF47jeSpLcHzWkMEqP5oHZRUSMHqr5MOCFHdrXyEst9A8EkU76X7KMCnpKcQpmYCsy0IVWcOVnMNauZQfr4iJVjmmciOUNxBL5DXAhNApgPkqlMcZwEEspIyuQu0ruo5gfbjQ/s1600-h/Chevy+S10+Forward+Rear+Battery+Rack+013.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh9ql4l4yuoOrR4UG_RgtOpOA2Y0iFwo1BJRcT4VJwQJpaiupImQxqNqxblZmeNrmriVwbS3l6umwR_UHWbXJL8Op2iuzW4x0ZWisB3gSrfvgcJ2Ai55vrv-W-iRScNa8E2K7o9P7grzAA/s320-r/Chevy+S10+Forward+Rear+Battery+Rack+013.jpg" /></a></div><br />
<div class="separator" style="clear: both; text-align: center;"></div><div style="text-align: left;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh7Cw1EFq0BpJTLg09muWGz5srQr12Wg-uawzyQhzrfYYFZub9hTx5M0SnUDEtZWS4KHzIngz9OnMNC8meSbb6Q_JihG6yXmNmU_gmsmrIKCP3FuZpLy8lcw9GoyRNDwZO2WX75clww4Eo/s1600-h/Chevy+S10+Forward+Rear+Battery+Rack+019.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><span class="Apple-style-span" style="color: black;"></span></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh7Cw1EFq0BpJTLg09muWGz5srQr12Wg-uawzyQhzrfYYFZub9hTx5M0SnUDEtZWS4KHzIngz9OnMNC8meSbb6Q_JihG6yXmNmU_gmsmrIKCP3FuZpLy8lcw9GoyRNDwZO2WX75clww4Eo/s1600-h/Chevy+S10+Forward+Rear+Battery+Rack+019.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiH-VAJz7vYo_e9pozu78QdEP3OCODOn88de8Wo2KuDOlWmVHne3ullWwOSuMgOl0RIlzsNEd8-NFXbMy6w0rIzd4Aowv0DqltnNjZC7vhBdGE9ZL9Ba545JFlDTlvIyIm0Vvs9WDd8oGQ/s320-r/Chevy+S10+Forward+Rear+Battery+Rack+019.jpg" /></a><br />
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<div class="separator" style="clear: both; text-align: left;"></div><div class="separator" style="clear: both; text-align: center;"></div><div style="text-align: left;">The four U supports are complete. They will be welded two on each side.</div><div style="text-align: left;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjEWeIzbBzalWfRIXgzp7legjXQhSSzs_ho1Mw5LWDOB0FiqALE3eN1TyJoHj3pBjVceUXMFZWisSV-7byVAhD-6LcPEsIN-K94nsN5KE2xN_CQUJrcTPupXBdwPzG4ZgcaGUmCAzOkQ8g/s1600-h/Chevy+S10+Forward+Rear+Battery+Rack+028.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><span class="Apple-style-span" style="color: black;"></span></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjEWeIzbBzalWfRIXgzp7legjXQhSSzs_ho1Mw5LWDOB0FiqALE3eN1TyJoHj3pBjVceUXMFZWisSV-7byVAhD-6LcPEsIN-K94nsN5KE2xN_CQUJrcTPupXBdwPzG4ZgcaGUmCAzOkQ8g/s1600-h/Chevy+S10+Forward+Rear+Battery+Rack+028.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQ7JLFLdmkAaA9nFLQMVZ5lEVvK95a2zNLt7U7vaGx5mwb6iCPy7foSnTwiprebYlsnIQAfIyEHfkzKOmZxqnvJxuXeIdWm86qju9QbkYOrnf-3RHJ0A__X9rRJ4R96-VahPAaTOTTg_A/s320-r/Chevy+S10+Forward+Rear+Battery+Rack+028.jpg" /></a><br />
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<div class="separator" style="clear: both; text-align: left;"></div><div class="separator" style="clear: both; text-align: center;"></div><div style="text-align: left;">Then I cut and bent the two longitudinal supports.</div><div style="text-align: left;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjM80eiNbb3QCELH1HUi2X7IR8IzAhCdfSNmqjPTbjbqT0wRKRSfCB6GR1UAgem6sEEa00bcHIIB93T4ZIIjN7YfcFbKCx18W9bPLUP8mfWvsGxKpDm8HzCu1LFuJfzS0LgeuAM_soI4ng/s1600-h/Chevy+S10+Forward+Rear+Battery+Rack+036.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><span class="Apple-style-span" style="color: black;"></span></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjM80eiNbb3QCELH1HUi2X7IR8IzAhCdfSNmqjPTbjbqT0wRKRSfCB6GR1UAgem6sEEa00bcHIIB93T4ZIIjN7YfcFbKCx18W9bPLUP8mfWvsGxKpDm8HzCu1LFuJfzS0LgeuAM_soI4ng/s1600-h/Chevy+S10+Forward+Rear+Battery+Rack+036.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRX1yueVbPyyubv1rbtT0Z7op_Wh9yuYfWwJonO9BX1MfO8cmCCTLC2uDXO3iJn4L5AawgQoxvdzxKj7FmBI4eV27ijUBvlH6AysN_glTfOZ0D36FTmV4384N962RTAVnA8gB6g0L7DdY/s320-r/Chevy+S10+Forward+Rear+Battery+Rack+036.jpg" /></a><br />
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<div class="separator" style="clear: both; text-align: left;"></div><div class="separator" style="clear: both; text-align: center;"></div><div style="text-align: left;">And thats it...in the next session I will weld them in place and finally be done with the rear battery racks!</div><div style="text-align: left;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhgzQ0sauipEAOEMur26-vxAZfi4hmEz5MHGESQXXksaxWzc0FG02g0mvi4VCrLyPH9-48W1ar5pvdwrGJhqszEWnFU0uSz1SxNJwD3K4z8bYKY-gB6v-uiKu6GwHSAndyiBk744aWKyEw/s1600-h/Chevy+S10+Forward+Rear+Battery+Rack+038.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><span class="Apple-style-span" style="color: black;"></span></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhgzQ0sauipEAOEMur26-vxAZfi4hmEz5MHGESQXXksaxWzc0FG02g0mvi4VCrLyPH9-48W1ar5pvdwrGJhqszEWnFU0uSz1SxNJwD3K4z8bYKY-gB6v-uiKu6GwHSAndyiBk744aWKyEw/s1600-h/Chevy+S10+Forward+Rear+Battery+Rack+038.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEinvV_eTOVKL2z9oZ_l0tG0K5w6FC1A1vkU2_K9Kl45RwgM0kKVyfs_Jq0zHBsE10zm4ECrx4FWhyBf7a1KrOscatlLj4QYdU8iWLzA1y6lqFAaiw5v9XeaQnDDvti6RXfI6vAtQGA0EMs/s320-r/Chevy+S10+Forward+Rear+Battery+Rack+038.jpg" /></a><br />
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<div class="separator" style="clear: both; text-align: left;"></div><div class="separator" style="clear: both; text-align: left;"></div><div style="text-align: left;"></div><div style="text-align: left;"></div><div style="text-align: left;"></div>Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-8244815155369495435.post-31107773272414213082008-09-13T23:46:00.000-07:002008-09-28T21:51:39.621-07:00Build Session 17 (60 mins): Rear Battery Rack Complete<div class="separator" style="clear: both; text-align: left;">Yes it's been a while since my last post. Work is extremely busy right now but I will attempt to make some amount of progress and post at least every week or two. We'll see...</div><div class="separator" style="clear: both; text-align: left;"></div><div class="separator" style="clear: both; text-align: left;">This month I was able to complete the rear battery rack. I made some size modification on the original design to maximize the space for additional LiFePO4 batteries. My current plan is to purchase 45 Thundersky 160ah batteries. I will install 32 of the cells in the forward rear boxes and the remaining 13 cells in this rear box. I estimate the the rear box will hold 34 which I plan to use in the future if I add more cells for a higher voltage system.</div><div class="separator" style="clear: both; text-align: left;"></div><div class="separator" style="clear: both; text-align: left;">Removing the rear cross member support...</div><div class="separator" style="clear: both; text-align: left;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhjmFwLPNksOBCiW57k2zaf_BBsj1HXg2t8CDLcMW0udhMcbwWthCV-rwnGd1v434PwYA0OPpgafpziBn_Lz9f1-BQTq-TqungMPMrQ3sdK2vZ6O_8y-zIyxHK9qRLl7sGE0XqB7rCZE1A/s1600-h/Chevy+S10+Rear+Battery+Rack+006.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgyIQ0j8V75602shS5C2lJb35_iwuhN29ioIKl2PCoJSLsLZ-aqwwG0httrS718kpDqPg972Jpx8QSv9RolL9H6hVAaWtRiniWw52t5Zf_6swLQHj4CRdaaru1MNPxCBFf486YkvgHGinA/s320-r/Chevy+S10+Rear+Battery+Rack+006.jpg" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjcfxetKHrVlU1RcR0TlNEVoC9J-L0-ckltGheN_Xnwi2J_Ns9njOK1qQPo0P1oFUJVLuo8NUulPNUWbieEdW0qPb3I-cbIfHM6L9ZFOl0Xjxus1FBrCv15lb1TonAGUhYxgICRooLmwy8/s1600-h/Chevy+S10+Rear+Battery+Rack+011.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"></a></div><div class="separator" style="clear: both; text-align: left;"></div><div class="separator" style="clear: both; text-align: left;">Cross member removed...</div><div class="separator" style="clear: both; text-align: left;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjcfxetKHrVlU1RcR0TlNEVoC9J-L0-ckltGheN_Xnwi2J_Ns9njOK1qQPo0P1oFUJVLuo8NUulPNUWbieEdW0qPb3I-cbIfHM6L9ZFOl0Xjxus1FBrCv15lb1TonAGUhYxgICRooLmwy8/s1600-h/Chevy+S10+Rear+Battery+Rack+011.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiqGjBlLTevQXpTQn-XeNEWuoYipPJ9JkYyMFUYlz3Tim40TTQ5X4egE-p7C4xcBWv58DYt2dPGMcDAPKENbx1nVy4RFJYKtdgGbkkzUbpHBc1D-_p9xk_nBkOJ62urIpDvYrOQsCs1Epk/s320-r/Chevy+S10+Rear+Battery+Rack+011.jpg" /></a></div><div class="separator" style="clear: both; text-align: left;"></div><div class="separator" style="clear: both; text-align: left;">Working on the final two rear rack supports...more bending.</div><div class="separator" style="clear: both; text-align: center;"></div><div style="text-align: left;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4RIn1aiziNKWjz2pLBD2ouolddIRcq_9uDDsLWCL_WF1AXTtZI2P4MGq_XJfvf2oVxd5kYIpZhFQCvNss6_h0meYpYha36BYNvoplG5ZxbglmRS94KisZaSxp-Cvbl5UAvtJZ_QbyaPc/s1600-h/Chevy+S10+Rear+Battery+Rack+017.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><span class="Apple-style-span" style="color:black;"></span></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4RIn1aiziNKWjz2pLBD2ouolddIRcq_9uDDsLWCL_WF1AXTtZI2P4MGq_XJfvf2oVxd5kYIpZhFQCvNss6_h0meYpYha36BYNvoplG5ZxbglmRS94KisZaSxp-Cvbl5UAvtJZ_QbyaPc/s1600-h/Chevy+S10+Rear+Battery+Rack+017.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg0s3dQLq1f-UQMHRmDxAYSXG_3F4G057drFd-50A-KD3QhmjcAzYcjOIgF3mbKU6Q257klcwSym44pVb3dy6VLKBeKu0lFeQhI4ZWvR9w5Q4fz1PIU4aZEI2Xp91FHwPQbc5BTtrcZc8M/s320-r/Chevy+S10+Rear+Battery+Rack+017.jpg" /></a><br /></div><br /><div class="separator" style="clear: both; text-align: left;"></div><div class="separator" style="clear: both; text-align: center;"></div><div style="text-align: left;">I made two just like this...</div><div style="text-align: left;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhe5m1VuPc_EwHKz0xMgR9wrYaaPX28N2p8eaHM7W3SWWEnXHgtIDOk9d-wGdzNPuFWnvXgTl0u3tx3oRzqqCscp31vkx_Z7oP4xMEfTywQbltgvgLnugobSnOUBbsoSjd_p1mCHxAj6k4/s1600-h/Chevy+S10+Rear+Battery+Rack+019.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><span class="Apple-style-span" style="color:black;"></span></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhe5m1VuPc_EwHKz0xMgR9wrYaaPX28N2p8eaHM7W3SWWEnXHgtIDOk9d-wGdzNPuFWnvXgTl0u3tx3oRzqqCscp31vkx_Z7oP4xMEfTywQbltgvgLnugobSnOUBbsoSjd_p1mCHxAj6k4/s1600-h/Chevy+S10+Rear+Battery+Rack+019.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhi9yIHY0P47y5DVMsdaa2M-XcKQCgy64my7xf4DOheJAsqUWr1u9MMoykdYp-ej2dpJZ1WjhDA0L3pue1eYVC6lT4x2JU398JhyjvIGGuJowkqexltN5Sv3qLtE0Jewb54RlI-AghxLtw/s320-r/Chevy+S10+Rear+Battery+Rack+019.jpg" /></a><br /></div><br /><div class="separator" style="clear: both; text-align: left;"></div><div class="separator" style="clear: both; text-align: left;"></div><div class="separator" style="clear: both; text-align: center;"></div><div style="text-align: left;">And installed one on each side as depicted below...This will keep the batteries away from the rear shocks.</div><div style="text-align: left;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5XapDHQ4Hir1yE0eHNEPAuUtJbA9ZWxhQraxUDNeFen8puJ74evkuXCrfNa19_j0vMlfqC6ni8HDmxy7T8UymkP2fG_BwyOOn7JNhbt06hoij5G2HVw2DDJcdqSsKo5Js-A1-d4IM7kw/s1600-h/Chevy+S10+Rear+Battery+Rack+029.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><span class="Apple-style-span" style="color:black;"></span></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5XapDHQ4Hir1yE0eHNEPAuUtJbA9ZWxhQraxUDNeFen8puJ74evkuXCrfNa19_j0vMlfqC6ni8HDmxy7T8UymkP2fG_BwyOOn7JNhbt06hoij5G2HVw2DDJcdqSsKo5Js-A1-d4IM7kw/s1600-h/Chevy+S10+Rear+Battery+Rack+029.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh3UI0fcaF588hyzt19_fFsczhOQaWhv1zjjPoiEV8oa18BHZIuDqd7zpz7xPXVQEk_IJ4Ki0qajcHlCU7t18Ph6eQtfQnK-0Y3ycBMG5fIOJbz7J5e3Y4DdLpJqdfFtFNrLKNoVGFLjig/s320-r/Chevy+S10+Rear+Battery+Rack+029.jpg" /></a><br /></div><br /><br /><div style="text-align: left;"></div>Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-8244815155369495435.post-48129864512177623062008-09-09T10:33:00.000-07:002008-09-09T17:02:16.757-07:00Lead Acid or LiFePO4 (lithium Iron Phosphate) batteries?<span class="Apple-style-span" style="color: #333333; font-family: 'Trebuchet MS'; font-size: 13px; line-height: 18px;"><br />
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<span class="Apple-style-span" style="color: #333333; font-family: 'Trebuchet MS'; font-size: 13px; line-height: 18px;">In a previous post I indicated that I would most likely purchase the the Trojan T-145 Deep Cycle lead acid battery <span class="Apple-style-span" style="color: black; font-family: 'Times New Roman'; font-size: 16px; line-height: normal;"><a href="http://www.trojanbattery.com/Products/T-1456V.aspx">http://www.trojanbattery.com/Products/T-1456V.aspx</a><span class="Apple-style-span" style="color: #333333; font-family: 'Trebuchet MS'; font-size: 13px; line-height: 18px;">. They are supposed to be one of the best deep cycle sealed lead batteries. They are relatively cheap (approx. $3000 total for 24 batteries). Unfortunately, they are also EXTREMELY heavy weighing in around 1700 pounds. Added weight will decrease range and performance. Based on my calculations and verified by several EV'ers that I have contacted I may only see a range of 40 miles using lead acid batteries. While this may be enough to support much of our daily driving it just doesn't feel like enough for me. Especially when you combine the fact that these lead batteries require regular maintenance (watering) and will degrade over time when not fully charged. </span></span></span><br />
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<span class="Apple-style-span" style="color: #333333; font-family: 'Trebuchet MS'; font-size: 13px; line-height: 18px;">There may be an alternative... Lithium Iron Phosphate batteries. This battery technology suffers from none of the pitfalls that I mentioned for lead acid batteries and contains many times the amp hour capacity. Plus lithium phosphate cells are 20% of the weight of lead acid batteries which will increase performance. </span><br />
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<span class="Apple-style-span" style="color: #333333; font-family: 'Trebuchet MS'; font-size: 13px; line-height: 18px;">I have been researching Lithium batteries for a couple of years and many of you may remember that Jared and I built custom A123 Lithium Nano-phosphate battery packs for our electric bicycles a couple of years ago. The batteries were extremely successful but a lot work, soldiering, etc... In addition, the A123 cells are very expensive. To achieve a range of 75 miles in my S10 EV I would need well over $20,000 worth of A123 cells that must be surface welded "soldiered" into custom packs.</span><br />
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<span class="Apple-style-span" style="color: #333333; font-family: 'Trebuchet MS'; font-size: 13px; line-height: 18px;">Recently, however, I have rediscovered a potential alternative. Thunder Sky (<span class="Apple-style-span" style="color: black; font-family: 'Times New Roman'; font-size: 16px; line-height: normal;"><span class="Apple-style-span" style="color: #333333; font-family: 'Trebuchet MS'; font-size: 13px; line-height: 18px;"><a href="http://www.thunder-sky.com/products_en.asp?fid=66&fid2=70">http://www.thunder-sky.com/products_en.asp?fid=66&fid2=70</a></span><span class="Apple-style-span" style="color: #333333; font-family: 'Trebuchet MS'; font-size: 13px; line-height: 18px;">) LFP cells. I did a little research on these cells a few years ago but found several people who were having problems with some cell batches. However, apparently, newer versions of these cells are popping up in a few Electric Vehicles around the globe and appear to be performing quite well. </span></span></span><br />
<span class="Apple-style-span" style="color: #333333; font-family: 'Trebuchet MS'; font-size: 13px; line-height: 18px;">The cells are manufactured in China. I have contacted their primary distributer and it seems that I could get my hands on these 160 amp hour LiFePO4 cells for about $9,000+ shipped to nearest SEA port. I estimate about 75 to 100+ miles range for this amount. Plus no soldiering hundreds of little cells as the Thunder Sky cells are manufactured in large form factor. Just 45 cells will be tied together with bolts and electrical cable. I'm considering purchasing even higher amperage 300 amp hour cells which would cost more but could increase my range to possibly 200+ miles. Yes, I'm drooling...</span><br />
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<span class="Apple-style-span" style="color: #333333; font-family: 'Trebuchet MS'; font-size: 13px; line-height: 18px;">Anyway, I have been reworking my battery rack design to accommodate either battery technology in case I actually get my hands on some of these cells. :)</span><br />
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</span>Unknownnoreply@blogger.com4tag:blogger.com,1999:blog-8244815155369495435.post-68426379735385489172008-09-06T05:15:00.000-07:002008-09-09T10:33:30.968-07:00Adapter plate is here...A couple of weeks ago I sent the clutch disc from my S-10 (actually I ordered a new one and sent that) to a machine shop specified by EV-America. They disassembled the disc and milled out the a the center portion of the adaptor plate assembly from 1/2 inch 6061 aluminum. In the near future I will attach this plate to my S-10 transmission, take some measurements, and then mill the transmission mating holes for attaching the plate. Then I plan to cut down the excess around the corner and perhaps follow the contours of the transmission bell housing. After that I will attach the Advanced DC 9 inch FB1 electric motor to the adaptor plate and transmission.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj-NUOX0O_ypEjMCw80zbxwmcY1Dp7q5Yx6v_5NAMA_F2m9vqGuvcCyPXAXWlvef66hUxEnwhT_dyVNn0Ffv5FCCd4mgbbGOXFnb0Qe43gr7DL2RZLHpT3GbS0e5gc8Ep8ybKp1lrJgkmo/s1600-h/Adapter+Plate++3.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjMggrlJaiY0Op7zJBDTZNrgybGFjx4XR7fmXuWySTcYmrTJvN-K7TPcPMR7YTrtYDPyJMpZuBltUXOUMcyVkEs4wQxrLlsqk9ILF5pj0qxr5ChW2WXbih7fIMILe39VvSRZTBvDRhzpn4/s320-r/Adapter+Plate++3.jpg" /></a></div>Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-8244815155369495435.post-59665262611103130722008-09-03T21:40:00.000-07:002008-09-04T14:45:44.592-07:00Build Session 16 (90 mins): Rear Battery Rack Welding Cross Member<div style="text-align: left;"></div><div style="text-align: left;"></div><div style="text-align: left;"> Yes, I'm still working on the rear battery rack. :) One more day and I should have the rear rack finished.<br /><br /></div><div style="text-align: left;"> </div><div style="text-align: left;">First I prepped the flat bar cross member that I bent yesterday. I'm using the wire attachment on the Makita to remove the rust.</div><div class="separator" style="clear: both; text-align: left;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjCLLt-qj_6yHQiIujIMy6sXw0yJbDqYNCBaU92Zp22DkZbKM3v0vwei9noLhDjniaTSqT8OmMwy0wISzxTcekOtk_bXnI6A3TnKF-ufdLf0TVi8ZMTNUGzP7GjvDfL1ymMdJD4FqfEX-Q/s1600-h/blog+Chevy+S10+Rear+Battery+Rack+001.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhd13dTzfEu8aWnOC3KW8s5k1cqPf4BviBf-0aETk6_BjvonL6xMw1aMr-uFNPOIYj4O0S1fUrZSzU4cm6qI-kh0UziIB3_TOTKc_XkgBKi7K8tkxpVEb0mMhoX9hpfWnXkRkkUCnv1Brs/s320-r/blog+Chevy+S10+Rear+Battery+Rack+001.jpg" border="0" /></a></div><div style="text-align: left;"></div><div style="text-align: left;">Prepping the frame...</div><div class="separator" style="clear: both; text-align: left;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhNx2AtIwfOQgh-0ybs-gcCRWiFRuFcaxU0CVyMa72bSr9gummT-QfI6MDVMoQGlrU-aI3BuD2Il_wXuSJdwAV1hj9rpuHT4EaL0ngi_p8FKYS0CI6EH2ipFi5Et6cIBS1FtIDXdU_XXcU/s1600-h/blog+Chevy+S10+Rear+Battery+Rack+002.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_sYhTDDsBjYe8tviduvkkn3JPFw5dyVrHvjVARE36hRGnSWIGxthTJV768jEkjr2XCAgz3taOoU_JSMvDS1ewOmRme9GblNXRZSwchKNZaBasdyfl92Jq8qXd-m5f5n35NnSVC83z-e8/s320-r/blog+Chevy+S10+Rear+Battery+Rack+002.jpg" border="0" /></a></div><div style="text-align: left;"></div><div style="text-align: left;">Measuring the distance at the top of the new cross member to make sure that its slightly more (1/2 inch) than the 31 inches at the bottom of the cross member. This will allow the battery box to slide in easier. The cross member is clamped into place and I tapped it into position with a hammer.</div><div class="separator" style="clear: both; text-align: left;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhgXp4C32zmMvxNDoSxiZoxajbDB6GkMkF82hxWuzivtUMfD1SEEh0x_tgsdTPRRgmcxZiaQDfcbWWLUV2JGKo5YT6p0POpGBgHRMdydpmkmi79jbjGf7LP860YitQblhBFvJKwGyOYyrQ/s1600-h/blog+Chevy+S10+Rear+Battery+Rack+005.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjSp-1uxLWqfz0t1saIxGk71TyuaPWTS4UqXd8w3VrrT53ZYVt3G-4WJsQ78_1Uk71xrtDTI85lsn32ObZQYiHEbP4LpAZ4_KHhTafAM7xFOfBaY9ozRwcJZ6eszxGCAHftUwUd4o0rWNU/s320-r/blog+Chevy+S10+Rear+Battery+Rack+005.jpg" border="0" /></a></div><div style="text-align: left;"></div><div style="text-align: left;">Then I welded the cross member into place.<br /></div><div style="text-align: left;"></div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgYb97Pnu-9BSGmRMKueDSIenN4vmtDuuF87XUD1E7QzUN4B4mDAmGFdtkYQdQ4yH0VlIf9bFd_M4q3Ry-gkPB4G21RLqtP3stxZJKXBRPJnfGCQA3In2EnmXI8IMG-iQCWtAfM-8FB__0/s1600-r/blog+Chevy+S10+Rear+Battery+Rack+008.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgYb97Pnu-9BSGmRMKueDSIenN4vmtDuuF87XUD1E7QzUN4B4mDAmGFdtkYQdQ4yH0VlIf9bFd_M4q3Ry-gkPB4G21RLqtP3stxZJKXBRPJnfGCQA3In2EnmXI8IMG-iQCWtAfM-8FB__0/s320-r/blog+Chevy+S10+Rear+Battery+Rack+008.jpg" border="0" /></a></div><br /><div style="text-align: left;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh58XrIBlEUUESdIP5GWLAymOWuXin-mBzSmv3jAbUDK_LsrBqpUZUVMVlKDXGcJNBPHOY2IFGKwb78FtxDAVe1RamxUdHJR2r0MjnhsYsgxxGgLxoz0ED9LMRO9kbmCGNtYkA6g_sOnKs/s1600-r/blog+Chevy+S10+Rear+Battery+Rack+012.jpg" imageanchor="1"><img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh58XrIBlEUUESdIP5GWLAymOWuXin-mBzSmv3jAbUDK_LsrBqpUZUVMVlKDXGcJNBPHOY2IFGKwb78FtxDAVe1RamxUdHJR2r0MjnhsYsgxxGgLxoz0ED9LMRO9kbmCGNtYkA6g_sOnKs/s320-r/blog+Chevy+S10+Rear+Battery+Rack+012.jpg" border="0" /></a></div><div style="text-align: left;"></div><div class="separator" style="clear: both; text-align: left;"></div><div class="separator" style="clear: both; text-align: left;"></div><div class="separator" style="clear: both; text-align: left;"></div><div style="text-align: left;"></div><div style="text-align: left;">In case you're wonder what welder I'm using...</div><div style="text-align: left;">It's a Lincoln Power Mig 140c Welder. I'm not using MIG right now just .035 inch Flux Core Welding Wire and it seems to be working great for this application. The bottle on the back of the welder currently is Argon which I use when I am welding aluminum. I use argon with the spool gun pictured below.</div><div class="separator" style="clear: both; text-align: left;"></div><div style="text-align: left;"></div><div class="separator" style="clear: both; text-align: left;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8WtPX_YEIJB-m9-VfTbe5G6xM6qAUwdg7n2BonVFi0OgHceGObYp0Mz8AASWvvB2CMoL5j7y2zFuYuZ-dKYmbZvF0mFHj5_pnw-dqljH7ewx_aY5pzWNeko19dUkccmmyU5nqsHK_aEw/s1600-h/blog+Chevy+S10+Rear+Battery+Rack+009.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiF7iJvbqgRFJZIluVdCGKRQ2Dy3cmr8GEk1yZCDVhdySykGTXTIV5jZMLbTE6r0zm4vZEETgCJ8AqdJu-7T9SNKuGhl4l2xF_EV3738Jrh170WsRK7y3GJkkjO_450LFcTkufykirsgKo/s320-r/blog+Chevy+S10+Rear+Battery+Rack+009.jpg" border="0" /></a> </div><div class="separator" style="clear: both; text-align: left;">.035 inch Flux Core Welding Wire </div><div class="separator" style="clear: both; text-align: left;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgZ3uRiy-NpektEZu45QVVWTr5149VJOvk7t7DX_r-xcIGJlMH7m3XxSRQgpYjGPjxGeltMD6_DkiL9VxbUBwErlTbraSVey3FhMCxT5yDTvAb4pKthxcqPnpCzMDwlAeazIaNtN7vEzLs/s1600-h/blog+Chevy+S10+Rear+Battery+Rack+015.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgqyD5DUa_9MeGhBKrr9eTPP1D693mLz_g_bQ6RCiY2fZNoyFQ2J6dR1VL7HG-FgbqR-Dnz0UrVEyiVvUFY090oz_c6Cw1cjLpDrjMXFEVBG_ZxyqYecpQKCaM5ztK52H1EA8bsww1Sl4A/s320-r/blog+Chevy+S10+Rear+Battery+Rack+015.jpg" border="0" /></a> </div><div class="separator" style="clear: both; text-align: left;">100 SG spool gun used for welding aluminum and other types of metal.</div><div class="separator" style="clear: both; text-align: left;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi05ewxQV5kAZQsUGO0Qf_ZxSKK83xNStxOPiI2K38Xi5I3yPJsRGdsQmLYmedqUGP0RQ9n4XNPij3bBgJ_n0wkNn6JrY9smiUGqH1O0F3KjmaOjEzFuv9sCx9xxBhORQN94ABbuVMfjgU/s1600-h/blog+Chevy+S10+Rear+Battery+Rack+014.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEis0YBijFZ_EmXz7yauam1UR904FFTm7qeG9lGn9FjarcDs3uiru_ZM_VKUTEzEhK3byQp1HK465X815HedvvxNI9IZnm-KEK-EEGvnXzvkx7m-YCmX2eQnPyHYX2u41wI8AqcHbl46r6w/s320-r/blog+Chevy+S10+Rear+Battery+Rack+014.jpg" border="0" /></a></div><div class="separator" style="clear: both; text-align: left;">Anyway, back to business here...Then I wire brushed the area where the flat bar cross member supports meet, clamped them together, and welded all three of them in place. That's it for tonight.</div><div class="separator" style="clear: both; text-align: left;"><img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjMWGESqza6hs86J96wkohiR6i0evQVeVMV49K1WyAQzTbZpRu-UWKAd6zadrFturYj-dRNIawGOzXhF0QEli5Zd33ILv1sSjyolmvuL6IGu6StTDCGK9O7dw2LWsOADCUyywLDc_NHCTY/s320-r/blog+Chevy+S10+Rear+Battery+Rack+016.jpg" border="0" /><br /><br /><div style="text-align: left;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi1U0hcS2Et0qEyCRoQiSj78A1UJAC_dRLnkovkODKGaB8ecF74HX8l4fjc30DbxF3bObrZ3QJ-pu4zmyDGU52BwJi5QRZ_dLLeJ3rrXQ-_yGHDIV10YyMJJnm0TtwUm_srXgT0HMZEFrA/s1600-h/blog+Chevy+S10+Rear+Battery+Rack+017.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhPmSP4X0zc5n-GqPeFQFZ_4pJqCz2RkOcoW3Iw8yQ4yQfh2e88C2wtk_stIMIwMt1T3LlRqRQlHWKKyHveByZYmAv0NRgGIf8gwfJ-J77hnCTKT71LcfBDi_dptJjUU4stiRC16nbmEYg/s320-r/blog+Chevy+S10+Rear+Battery+Rack+017.jpg" style="cursor: move;" border="0" /></a><br /></div></div><div class="separator" style="clear: both; text-align: left;"></div><div class="separator" style="clear: both; text-align: left;"></div><div style="text-align: left;"></div><div style="text-align: left;"></div><div style="text-align: left;"></div>Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-8244815155369495435.post-2668798066881787652008-09-02T20:57:00.000-07:002008-09-04T14:18:57.574-07:00Build Session 15 (45 mins): Rear Battery Rack Cross Member BendingNot much time again tonight...but it was enough to cut and bend a piece of 3 inch flat bar for the rear battery box rack. This piece will provide cross support for the rear battery rack. The flat bar is 1/4 inch thick. I cut it 68 inches which turns out to be a 1/2 inch or so to long (I'll fix that tomorrow when I weld it in place).<br /><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbx8qqCEDdJtmZCFsEh1diKEft0U9-w6VNsM_bqshAuaidO4OqFU2qbMQ6ZdFV6KnSZE7tRHYcwICGJLS23_TTynCiCDsHex0Ii_TI0RLJhlKzX9yXlEGjtKSFQ0Tt0h28dMbL8xJf1QY/s1600-h/blog+Chevy+S10+Rear+Battery+Rack+001.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZ5wZrqm8tnymdVPn2t9NNaf4e-87Gz3xFkxjvvLmKMXzQxuESbY1U6fIOjNv73B4rgvpjDSmkMXEvL9iFGYlcQYn64N6nD6ZySW0QHSjrnV3FGSPxI2E4Up_A1tDbp5Ds0ujFWuwFcyA/s320-r/blog+Chevy+S10+Rear+Battery+Rack+001.jpg" border="0" /></a> </div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;">I convinced my oldest son Matt to step away from his laptop long enough to work square up this piece and help me bend it.</div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg0IAFHDSG6-5kKzNBBV0YB_yX3drXbA_SM7JpG0-zSKuAzV1Lk6ZdAovt5uzd33Y-WcCjj2HMHDL_IkEQVLfeycy0QfsPPSJ0F7RDnwEIEqW1osPpuhaiPo1EnUqNK2vfnJuuJ26Do0co/s1600-h/blog+Chevy+S10+Rear+Battery+Rack+003.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi7mon-MG7G9o47CAjEBNzbPWPTm_xjmGAfwxBHwjsK9BCa3GqRrN_-7bVGG0wLZa7WhnaLF2J_Hggon__g9DCJAbFxlifMVwMdfK8cFrTotkPBDvA9VtZP1FYY10EZYfvkDjeRjJ04LQQ/s320-r/blog+Chevy+S10+Rear+Battery+Rack+003.jpg" border="0" /></a> </div><div class="separator" style="clear: both; text-align: center;">Using the torch to heat the steel... </div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgvZ6LMpCXDTMAIh8YiLDDqgY015dXrWGQFU0AUA0U8BFHXI1eY9a2Wm8K7I3nWJnmbZtf7g1V7i-fIrbQefOKRyvtbym_5ZgpuUUhd5Mnn-Bs-Bs9krL4DJKvfs6U34fqFAv22KzbHmqU/s1600-h/blog+Chevy+S10+Rear+Battery+Rack+009.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgk1a74z0WZvls-ABV-lozKxX2D9VnClNPizy7J958cuQB70cqwO3iTZQvIPWxpJBy6UDoBvSPh1urfMoNFmt8oidBaZyhr3eqc8BeFAojS1YOpDROdu3WfE4_8eTFnkmJo0SuavpHBEPg/s320-r/blog+Chevy+S10+Rear+Battery+Rack+009.jpg" border="0" /></a> </div><div class="separator" style="clear: both; text-align: center;">Matt is learning how to use the torch...he did a great job! </div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJR-ga6Vd-80zw7xKR87-DxJkjxuvJS81oijiMP_LT3iREZ9KQfxT9VtlPFtkXBpIoqaH_DK8lRBA-zSaZ2TlI9XHew4zzBuyqe8dr9z_GKGDv17j0fCuvmvdsyr7Mc2EcSUIaIbSDN7o/s1600-h/blog+Chevy+S10+Rear+Battery+Rack+014.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiC30ThtS4lEMhtWR48oxfdJEFhEaixhRsibkx4Z112qGF6r-QLovIxLCqe4OQm5-zBK8xlmmu-o1QfY8-N_-3kMOoLjYIPZRC18YNfarK7aeOXFhBpYA5O3tJ7GUUo656_2sj2HA5WXQc/s320-r/blog+Chevy+S10+Rear+Battery+Rack+014.jpg" border="0" /></a> </div><div class="separator" style="clear: both; text-align: center;">Me...trimming the acetylene... </div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi6xgv17uEv9OrVZWI4t3dA6yt1zewwEFPHeyZwqZvDsf8-u2bnVjGebDbGZDU6KjdCFH2YpryVdJH23SC4I5MeT4upumq5K1bh9SQYlVHk_NKpQLiJU-NU06MTcusgx2M9eTAM8mglSqs/s1600-h/blog+Chevy+S10+Rear+Battery+Rack+015.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgMLZXh7CpSKklR6v8UD0xV9MZ807zXVQXtv4FSJTa5gi7NneVUHb-WawHQOpKz4-bBrGpZY1SpMoFgdSHW_-EmFMPq5aLS89qo8UZ1iZidM9PR1pJXEzb62Hfj6BV-WYBBrWg3cHIIXxE/s320-r/blog+Chevy+S10+Rear+Battery+Rack+015.jpg" border="0" /></a> </div><div class="separator" style="clear: both; text-align: center;">Preparing for the third bend... </div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjCRGZ9s0d3YdCsXIglIT96vqtaihgIlxFYiYKO2qDmd5IKPbgmkrs-ht3TgshY2z2ILH6o1MZt02_SFHURhQqUhRyEdBRCPGZhkbTwIFsIw4DENDGmOataV7sQhaJxFLURnZN6bG5Wlnw/s1600-h/blog+Chevy+S10+Rear+Battery+Rack+018.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh0J553SLw6nYrSRKq9SsZlzLCTR9KR1q25HiKVfIRKmw6oInn3TLS_-zzA0P-sGcIs2XwtnuNZeKFHn6-JtmWYcCcU1uPNzPE-QKQ8iVJzKvtlui_AxsJaVMC29sTkPatNq4AcaNgw3LE/s320-r/blog+Chevy+S10+Rear+Battery+Rack+018.jpg" border="0" /></a> </div><div class="separator" style="clear: both; text-align: center;">Not much leverage so Matt used the sledge on this bend... </div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgkgpNXyd0fWga05SDf0BtKO_ZGmg6jGmgNWCwS3JUjPdqjA9KlKNpBmAo6JlgE3CQsvMayAWsORdA-T1pK07iKGVOG2S4TFNWJFQIrfQ3-JFTbfjNilXHye26LyXST0iKy2Oy3AANadWg/s1600-h/blog+Chevy+S10+Rear+Battery+Rack+022.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhcvfn38CUbtjaMZyGn4-iopIbiiXftYJ6O6pAjIVjYtOx8yTj2WzX7bkkxuelQaz881_yuCmAttk5hXdHGW1BE2Y2gR6Bh3MKHez7b0kc2PCKMAnWpMJvG0jjaiLLVlkpI5LxK9CjjWK4/s320-r/blog+Chevy+S10+Rear+Battery+Rack+022.jpg" border="0" /></a> </div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;">The new 3 inch cross bar sitting in place... I plan to trim the ends down an inch and weld it in place tomorrow. </div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiOyLPcFA0yqn5VUPm_TDRGD0fAvBTVis7L_v3UIHAlZ8JKJsxH-rSUGIw91Aleyom5iJ_c8yKSjU6eL7NnSKhPjumXOOM7oSFjH-t3XNTO3qCfVAeUgc3i4VlMCzH9QOnc-eGBNbaQ8M8/s1600-h/blog+Chevy+S10+Rear+Battery+Rack+024.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDoJdR1EZh7wJz32IKwQ0UKG66FUZtLv0jtVHn0RLmiPGwRPq-61jLP59yaKC1UiBCkjdX3B-aMJn4n3_PjxieXPAscf8YNYBhQaiUafS2U0H5L3a_dCSwSFaA65SXiXPPX9i3To2-Et4/s320-r/blog+Chevy+S10+Rear+Battery+Rack+024.jpg" border="0" /></a> </div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"></div><br />A video of Matt using the torch.<br /><object width="425" height="350"> <param name="movie" value="http://www.youtube.com/v/LpVUtVk1_dE"><embed src="http://www.youtube.com/v/LpVUtVk1_dE" type="application/x-shockwave-flash" width="425" height="350"></embed> </object>Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-8244815155369495435.post-33198192912944110952008-08-29T23:23:00.000-07:002008-09-04T14:14:59.433-07:00Build Session 14 (30 mins): Battery Rack Build Session 7Tonight I cut (most of) the rear support section out of the Chevy S10 frame. This piece needs to be removed to make room for the polyurethane battery boxes that I will build in the near future. That sums up my accomplishments for this weekend as I am camping with the family at Whidbey Island.<br /><br />Using the Makita with a cut-off wheel...<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh3iG38vz1CBqMObT5iGuEGmVOWLf2E4icsm1WsA4WyqhRIYqpDliFHFtp6Ml7u5InHZdG1FEXDJF9DGUVTIeDZXRr4jR7HxvT2a2qDPFINLEZJMBW1QUuKEPextjfAPjuRwfDQAlJDudM/s1600-h/Chevy+S10+Battery+Box+002.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhDhksYS2msbZMxs3EdBvtHqcUgH7tTFgSCgoE3fsrVN8BsUXG0gfwIuO8eIFlBu4e7_dML68w5-OiXg-Z4n17X_kaFEXAJSWqsGV2MUTkYiTqdL0FmVuQL_xfrPtoMZKNOPRy4QEhR3JA/s320-r/Chevy+S10+Battery+Box+002.jpg" border="0" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgAuquKthxGFO47IP0DG4N-zR-23E2LENiYXBUB_6JY09XXGIOVC9KOpumBA7yspwaw9MEfhOhrKrUTVXPgLBerO5fC345eb7NpVEILW7_QZsDdxfX-s_a-0w8Z8wBt3leHYlStAJxKKic/s1600-h/Chevy+S10+Battery+Box+003.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEidf_825qpjKVexvaYXTfS5M0Q4XHM2tiTyvcrHahkwCTlA5HJ-foLRvBIUghflDH8n2uYxNEKBVMcsqwbfaHVFDSVVnbDRe43g5VE1IDFL4MjmeYNm04hYO2QfJyKO9KM8UpEhsyT7JlA/s320-r/Chevy+S10+Battery+Box+003.jpg" border="0" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgT-tk52n9sjPjMTDT2s-l_eEAwrc2x-MSNbvDEkGW2IZ9GWnJEk9EkwBash6N6VoHCnXzfwOkzsuQTFN4uqJ8RSm-Xgl3JHaZ_q4v9vG3pCIypNIAjRh0vm8NqNbf9kR2B1ir8NeHArT8/s1600-h/Chevy+S10+Battery+Box+004.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgfd7FLjNh-qxIHwX0iTeSwKZ6glYBZiSVNiL-8JsKV06j4gMz4I5XW11BKjWjg6-8-PrCKPB-M4z4VpZN51NKjdwdYGiGzUHXO7z-uI9uOb4ZkaXQprAQg8YVwpW3CSLVvU9B78-Xc8T4/s320-r/Chevy+S10+Battery+Box+004.jpg" border="0" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg-PRzXvEpDReWW5Tc8EqDizZFAqEyeipAqVHSqi6rZeO1uoIWI0oklpI76vOsPaH6rqWK8-x_SXuYJ1N1XpImQFyNw0kQ0P-a5JBUKBWD4URDV5Vn2lnMWuSu1u_o1Jgxnci9XzYcCxxg/s1600-h/Chevy+S10+Battery+Box+001.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhkJtg8GE4tFGyxMkcDVIV57MEEXFIZI0FV01lJXOmeXStZW2B-6Nrwz7hQd5HdWOYA5hoL3Sfj_ls6kz6ttxzvdLq9HOz91jHxknoesmVixQdbFeXv8FlEj9LWxxNoayTrPhTbqInkKRw/s320-r/Chevy+S10+Battery+Box+001.jpg" border="0" /></a></div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"></div><br />Support section removed...<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi5vOFGF0TIlG4zu41X7HDWLnurcLhA2CybKfcaI5E9QNvAl3FhZSIbMLQ-X9B5Bx35lOPq6JdEEPq0bgTcVsCPzge7L0tyDJYIWFA7s0EdIY0BMI5hYtdvXhw4XholkgTGeya3VcniIBU/s1600-h/Chevy+S10+Battery+Box+007.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjV-Bk9Nbag_D-r42KMdFByQk1PRW3mewb9Ujw2Y0oz_yd53MA11sErFo0adLvOy-1NrAfV3SpeU-sWVyJIDIJe52ogY7lpcnH3qs_DQhP4K6vSYevmMd3y8RRsPKxrJPL2PCxOZ-tZf8g/s320-r/Chevy+S10+Battery+Box+007.jpg" border="0" /></a></div><br /><br />I plan to remove the rest of this support section after completing the rear battery rack and adding additional support to the shock mounts.Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-8244815155369495435.post-62301140452384841012008-08-28T22:00:00.000-07:002008-09-04T14:13:36.697-07:00Build Session 13 (1 hour): Rear Battery Rack WeldingBack from San Diego and ready to work on the truck...<br /><br />I did get three of the support bars welded into the rear battery rack tonight.<br /><br />Of course I wouldn't have been able to do it as fast without a little help from Tayler.<br /><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgHkEMNcSXa1nazVmOvZR-aZX3ivIfLeY2ELQYyWgapQQ58lOuZGCkqvWg1NFU4ZIoxVz8iSh_BSqHdigR1CW8bM7KaIz0IWVHhqVTSoEXQ-swRJyZ_hUyy_dvlZFO0xvoU8cjH9CBuKLg/s1600-h/Chevy+S10+Battery+Box+007.jpg"><img style="cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgHkEMNcSXa1nazVmOvZR-aZX3ivIfLeY2ELQYyWgapQQ58lOuZGCkqvWg1NFU4ZIoxVz8iSh_BSqHdigR1CW8bM7KaIz0IWVHhqVTSoEXQ-swRJyZ_hUyy_dvlZFO0xvoU8cjH9CBuKLg/s320/Chevy+S10+Battery+Box+007.jpg" alt="" id="BLOGGER_PHOTO_ID_5239829369637516754" border="0" /></a><br /><br />We clamped the "U" shaped pieces into place and squared and welded them to the support tubes (one side at a time).<br /><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhfto_Ffb4VDLEkDKuVYVf_Lg8_BIVqeVliaj13lYlYGP0cSg6gc1tLqoo6SHAjd51QXzs3o6T_BnNtueOudI7TtYVOkrJKUVlePUefh4cDK-fo4dol-LbXUXuh9zIPJYK01LpBFG_VQxE/s1600-h/blog+Chevy+S10+Battery+Box+012.jpg"><img style="cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhfto_Ffb4VDLEkDKuVYVf_Lg8_BIVqeVliaj13lYlYGP0cSg6gc1tLqoo6SHAjd51QXzs3o6T_BnNtueOudI7TtYVOkrJKUVlePUefh4cDK-fo4dol-LbXUXuh9zIPJYK01LpBFG_VQxE/s320/blog+Chevy+S10+Battery+Box+012.jpg" alt="" id="BLOGGER_PHOTO_ID_5239810038686459794" border="0" /></a><br />Notice the surface rust building up already...don't worry, my POR15 chassis coat epoxy showed up last week. As soon as these battery racks are done I will prep and paint. :)<br /><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjz5_ExxpGx9AM-YuLK4PT_FlxODlvPXCkglB7XEwue06CO_oEBmT1r6LIfqvtDN2c30Yn1FSifKbmC_eQNjbU2vojsBhyYK5MNyLmLZFUxKnJNopM8EMGN3Ym1h3QjrFhroOGpSL85i70/s1600-h/blog+Chevy+S10+Battery+Box+009.jpg"><img style="cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjz5_ExxpGx9AM-YuLK4PT_FlxODlvPXCkglB7XEwue06CO_oEBmT1r6LIfqvtDN2c30Yn1FSifKbmC_eQNjbU2vojsBhyYK5MNyLmLZFUxKnJNopM8EMGN3Ym1h3QjrFhroOGpSL85i70/s320/blog+Chevy+S10+Battery+Box+009.jpg" alt="" id="BLOGGER_PHOTO_ID_5239810023964463810" border="0" /></a><br /><br />Tayler with a wire brush...I wish that I could get her to scrub the dishes this good. :)<br /><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjBmQp4r78cBHSDbzonHoDPydqb6jdVzRYShGrkCXe-BEj3EvNxV1Ovz4YW3G5n_J-JfiFlKPlXowhIoPIeecHaUdZY_HcT063vbXhhyxMy3kjrxmeel7-9EbNlhdZUEZdrsg-5iIF0QkA/s1600-h/blog+Chevy+S10+Battery+Box+013.jpg"><img style="cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjBmQp4r78cBHSDbzonHoDPydqb6jdVzRYShGrkCXe-BEj3EvNxV1Ovz4YW3G5n_J-JfiFlKPlXowhIoPIeecHaUdZY_HcT063vbXhhyxMy3kjrxmeel7-9EbNlhdZUEZdrsg-5iIF0QkA/s320/blog+Chevy+S10+Battery+Box+013.jpg" alt="" id="BLOGGER_PHOTO_ID_5239810044998346690" border="0" /></a><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjV0eu3vGPJhyLbc8XBdbmFcJ-3IVgL1mHlY4S9xwOk1EsajO88kw2wsR3826azj-1uRG0zcPl-8vG4uodbgLvPtG8LL4hUz8-zgjK5rAps2OtA3wQ4SQYC3NIvHzb7HHWXrz4ispDCKXQ/s1600-h/blog+Chevy+S10+Battery+Box+015.jpg"><img style="cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjV0eu3vGPJhyLbc8XBdbmFcJ-3IVgL1mHlY4S9xwOk1EsajO88kw2wsR3826azj-1uRG0zcPl-8vG4uodbgLvPtG8LL4hUz8-zgjK5rAps2OtA3wQ4SQYC3NIvHzb7HHWXrz4ispDCKXQ/s320/blog+Chevy+S10+Battery+Box+015.jpg" alt="" id="BLOGGER_PHOTO_ID_5239812511406708242" border="0" /></a><br /><br />Using the Makita wire brush to clean up my welds.<br /><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgvxeS-dYu8yXvQ-d9rZToRGwKBU2Q7UB-k2enu2fjNmO8e2QwBmQ-0PhfhlyUHSMglFtKTtGX-PhBZbomXW4kPQa-1xP3RjVdj0FXT8G-7paRn20vqJ2nCHRLG56K4IrEBcyxRZEff84o/s1600-h/blog+Chevy+S10+Battery+Box+016.jpg"><img style="cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgvxeS-dYu8yXvQ-d9rZToRGwKBU2Q7UB-k2enu2fjNmO8e2QwBmQ-0PhfhlyUHSMglFtKTtGX-PhBZbomXW4kPQa-1xP3RjVdj0FXT8G-7paRn20vqJ2nCHRLG56K4IrEBcyxRZEff84o/s320/blog+Chevy+S10+Battery+Box+016.jpg" alt="" id="BLOGGER_PHOTO_ID_5239812521251830834" border="0" /></a><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgIS8UtwDhQPg9lgUeun41WGnOt697Y0sCExLxG-PFQkZGPQNFaZDhMqARr0ZlTMg7tc4LMLN82tHeXCQlrfO_PeTy7ZAD7g7M1efaIg05h3Y1ELmCNFWk91ufM9rrDbK1YX95y3l8dVUw/s1600-h/blog+Chevy+S10+Battery+Box+018.jpg"><img style="cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgIS8UtwDhQPg9lgUeun41WGnOt697Y0sCExLxG-PFQkZGPQNFaZDhMqARr0ZlTMg7tc4LMLN82tHeXCQlrfO_PeTy7ZAD7g7M1efaIg05h3Y1ELmCNFWk91ufM9rrDbK1YX95y3l8dVUw/s320/blog+Chevy+S10+Battery+Box+018.jpg" alt="" id="BLOGGER_PHOTO_ID_5239812525420163634" border="0" /></a><br /><br />Three pieces welded in place. In my next session I will build 3 additional pieces to complete this rear battery rack.<br /><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5AIEhMUOQ9Oh3PZzi-q6SVjcK_sCmcoa2roXf9a8JRQzyr648q5Ze4ifhp1tZjDN9PyAbaT78rVkDmO4fjMZdSNWRyDyaRqWiznOpg_MVzmbLIs2va_hvoBXHnW9yZDLqRmrGpb2Ib08/s1600-h/blog+Chevy+S10+Battery+Box+019.jpg"><img style="cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5AIEhMUOQ9Oh3PZzi-q6SVjcK_sCmcoa2roXf9a8JRQzyr648q5Ze4ifhp1tZjDN9PyAbaT78rVkDmO4fjMZdSNWRyDyaRqWiznOpg_MVzmbLIs2va_hvoBXHnW9yZDLqRmrGpb2Ib08/s320/blog+Chevy+S10+Battery+Box+019.jpg" alt="" id="BLOGGER_PHOTO_ID_5239812534282747394" border="0" /></a><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg4tRSctfjLF4CyJKzgu6eburoj7kCBPA4QAFZycjUyvNRfyjzojOsHBiQvtnyJ2pCfie8kxLPM7sPENxI_FJtVl0C98ef7PErGUZfvxEg6ZQAjqi5YmyODlsWaREnP5MbbSLVIh24dAaE/s1600-h/blog+Chevy+S10+Battery+Box+022.jpg"><img style="cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg4tRSctfjLF4CyJKzgu6eburoj7kCBPA4QAFZycjUyvNRfyjzojOsHBiQvtnyJ2pCfie8kxLPM7sPENxI_FJtVl0C98ef7PErGUZfvxEg6ZQAjqi5YmyODlsWaREnP5MbbSLVIh24dAaE/s320/blog+Chevy+S10+Battery+Box+022.jpg" alt="" id="BLOGGER_PHOTO_ID_5239813588271052706" border="0" /></a><br /><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhKexcvfjttpgCtjWTsPLvaAnVlRbCLhjvXnWZx0KLSdpmNFkIj-Nq2miIOF0Q951lMpEF_hYp6nRCMBmywoNCJTrrzF-Na0V5cBXDd25DNAu-Y6OTrpZzVZA0UnbQj6Z1FtZmQQMIN0RY/s1600-h/blog+Chevy+S10+Battery+Box+023.jpg"><img style="cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhKexcvfjttpgCtjWTsPLvaAnVlRbCLhjvXnWZx0KLSdpmNFkIj-Nq2miIOF0Q951lMpEF_hYp6nRCMBmywoNCJTrrzF-Na0V5cBXDd25DNAu-Y6OTrpZzVZA0UnbQj6Z1FtZmQQMIN0RY/s320/blog+Chevy+S10+Battery+Box+023.jpg" alt="" id="BLOGGER_PHOTO_ID_5239813594884234274" border="0" /></a><br /><br />The POR15 showed up! This will protect the frame and battery racks...plus it will look great.<br /><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEguw_D1rRxn3bAzaEwG8sxPY_gvV3HdsmtdEYmnBT93lBt9E1rGxvAfp-Pa6EHWwfsJMhen8F6Flq04KNZv7YT91t71ssl3NNywliTQ0vMLBAZTQyhQOV6K5Z3mjgTS3mae_ZkInoXoS2w/s1600-h/blog+Chevy+S10+Battery+Box+010.jpg"><img style="cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEguw_D1rRxn3bAzaEwG8sxPY_gvV3HdsmtdEYmnBT93lBt9E1rGxvAfp-Pa6EHWwfsJMhen8F6Flq04KNZv7YT91t71ssl3NNywliTQ0vMLBAZTQyhQOV6K5Z3mjgTS3mae_ZkInoXoS2w/s320/blog+Chevy+S10+Battery+Box+010.jpg" alt="" id="BLOGGER_PHOTO_ID_5239810028035610546" border="0" /></a>Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-8244815155369495435.post-53961921487526252082008-08-20T21:48:00.000-07:002008-09-04T14:11:37.319-07:00Build Session 12 (1 hour): Rear Battery Rack Flat Bar BendingWork has been busy so I haven't had as much time as I would like complete the battery racks. Now I am leaving for San Diego for a week so don't expect any posts until the 28th or so...<br /><br />I did get the rear box flat bar cut and bent into shape...My son Reece helped out.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgLGHmKcTvqMhky_5k4o5eLzzhJpQVojlsDjebUCJIRxU6zXuGsLF5Oar4ilC7_yog91hQbK6QIdV0P3XyDF42PtObl3XB1wK8Pzg8CMsGZAoSbP-l9kFmeRuje9xFqkZLgwvsuB0PUJOo/s1600-h/Chevy+S10+Battery+Box+024.jpg" onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}"><img alt="" id="BLOGGER_PHOTO_ID_5236834959005910562" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgLGHmKcTvqMhky_5k4o5eLzzhJpQVojlsDjebUCJIRxU6zXuGsLF5Oar4ilC7_yog91hQbK6QIdV0P3XyDF42PtObl3XB1wK8Pzg8CMsGZAoSbP-l9kFmeRuje9xFqkZLgwvsuB0PUJOo/s320/Chevy+S10+Battery+Box+024.jpg" style="cursor: pointer;" border="0" /></a><br /><br />We clamped the flat bar to an old steel skateboard grinding rail that Reece and I made a while back. Then we heated the flat bar with the torch along the bend line.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEicFIjmYE33ClFd95JaA5ZpYOPW-zgL9UDytjMTe7SGcHG3dPkkU1E5qN35_YvcFsNj__r414DGIkqjJNbWGE7Y2p1otGUjxq1MpeL-7CdPt5AV3Ak8orMXyLcMpP-wKcFknNCZqdfb4kI/s1600-h/Chevy+S10+Battery+Box+012.jpg" onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}"><img alt="" id="BLOGGER_PHOTO_ID_5236831445240141922" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEicFIjmYE33ClFd95JaA5ZpYOPW-zgL9UDytjMTe7SGcHG3dPkkU1E5qN35_YvcFsNj__r414DGIkqjJNbWGE7Y2p1otGUjxq1MpeL-7CdPt5AV3Ak8orMXyLcMpP-wKcFknNCZqdfb4kI/s320/Chevy+S10+Battery+Box+012.jpg" style="cursor: pointer;" border="0" /></a><br /><br />Then we bent it.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCy4mJ-2Zk8ceLlcQarcCDXlVY75g8Ay0S9frJU91I5c0MGusSQXtscAkg_L92c9OD_AgJnksZYt-UxYPDhWlsSm1JEM4LY5hdhBg2L8i7U1lMyMQ08m5XtPXzdMvQtts43cIhtmopIWE/s1600-h/Chevy+S10+Battery+Box+018.jpg" onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}"><img alt="" id="BLOGGER_PHOTO_ID_5236831464748723922" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCy4mJ-2Zk8ceLlcQarcCDXlVY75g8Ay0S9frJU91I5c0MGusSQXtscAkg_L92c9OD_AgJnksZYt-UxYPDhWlsSm1JEM4LY5hdhBg2L8i7U1lMyMQ08m5XtPXzdMvQtts43cIhtmopIWE/s320/Chevy+S10+Battery+Box+018.jpg" style="cursor: pointer;" border="0" /></a><br /><br />No problem...<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgm5pOxP8XXnNCvjw73fuPqMjy4WrM3wNSM-uXxZrF4d6MEPxkK33js6B922i5B0_oPrHCMm7RjQ6LhEcx3s4CCx7fGA-LO2ovt0VcpaIvmBFS7DG-ixmNSgytotkw0BQCZsrPG8eN4kbA/s1600-h/Chevy+S10+Battery+Box+013.jpg" onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}"><img alt="" id="BLOGGER_PHOTO_ID_5236831456510065698" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgm5pOxP8XXnNCvjw73fuPqMjy4WrM3wNSM-uXxZrF4d6MEPxkK33js6B922i5B0_oPrHCMm7RjQ6LhEcx3s4CCx7fGA-LO2ovt0VcpaIvmBFS7DG-ixmNSgytotkw0BQCZsrPG8eN4kbA/s320/Chevy+S10+Battery+Box+013.jpg" border="0" /></a><br /><br /><br />A second set of hands makes it even easier.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgpQMbf29bSlvYURd52nuFh5zjboq5WPE0o6PSq8cMp76A5RxmFDOCD6ojEGqmuZcfq6ymf2PUQWqLlh9QSdFY3FFCeCjkpbLHVY09lnPhWota9bc1bMRd9iG-MGQUY8cBdlXGHC6gAnpU/s1600-h/Chevy+S10+Battery+Box+026.jpg" onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}"><img alt="" id="BLOGGER_PHOTO_ID_5236831469527578434" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgpQMbf29bSlvYURd52nuFh5zjboq5WPE0o6PSq8cMp76A5RxmFDOCD6ojEGqmuZcfq6ymf2PUQWqLlh9QSdFY3FFCeCjkpbLHVY09lnPhWota9bc1bMRd9iG-MGQUY8cBdlXGHC6gAnpU/s320/Chevy+S10+Battery+Box+026.jpg" style="cursor: pointer;" border="0" /></a><br /><br />And here is the finished pieces. I plan to weld them to the rear battery rack support tubes when I get back.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiFT5Oa2fVLYkkPs996ES7SYZxj520Diz38IfxWOJ2rr_aop3ecwlKWBoZ7ZBDO4U25y7IMvBW-D4eJcgXMqOhcGCoLxL1jW5XI9uMU20Ei8jZG84dA8XCIOkGv4-m0rIVZ72VpgulPNRA/s1600-h/Chevy+S10+Battery+Box+029.jpg"><img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhaTCu6Xh79GEkI9oOsCc231ofuSjOSrjXbTTBw8AYN8m9mCtW4I5ppXpsWdxGUmeZxj0pGI-OMtWcPZ5mp170UAYIa65a16iRDXUieD9MMq4EB4iTwhyphenhyphenQ7wXpzDQOi7NFS_kkvT22rRx0/s320-r/Chevy+S10+Battery+Box+029.jpg" border="0" /></a><br /><br />More parts showed up today: Ceramic heater, volt gauge, ammeter gauge, heat shrink, cable lug covers, motor mount<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgivtorELS5L4SxyXzAEvy3OCbOekExVPYt30_zvcQZXb7QowxEUZn_l4_M5Fj2Zd05-nRZW9AMiyAfPUCmQfmHr8GGmFsSwWNuVzAS-Sh9E6krz1vq3JrVMlWIA1q8zKxUlEbLWm2DVKM/s1600-h/Chevy+S10+Battery+Box+001.jpg" onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}"><img alt="" id="BLOGGER_PHOTO_ID_5236834966342155730" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgivtorELS5L4SxyXzAEvy3OCbOekExVPYt30_zvcQZXb7QowxEUZn_l4_M5Fj2Zd05-nRZW9AMiyAfPUCmQfmHr8GGmFsSwWNuVzAS-Sh9E6krz1vq3JrVMlWIA1q8zKxUlEbLWm2DVKM/s320/Chevy+S10+Battery+Box+001.jpg" border="0" /></a><br /><br />...and the gas shocks & hinges for the lift bed conversion.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgEWxeBQyACBzP5sp9NLNo1deYJGy0ttqCCeqDc_Owp7UGB0LepciBZOUvITxDcLSjkm5wjMDQsW45O0W8FGsOE2ujE9jiuhX5OZFRhb2UGYDpwF5ggy43jrGz13GIVw7FncYIzyyoV-Xg/s1600-h/Chevy+S10+Battery+Box+007.jpg" onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}"><img alt="" id="BLOGGER_PHOTO_ID_5236834978695004770" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgEWxeBQyACBzP5sp9NLNo1deYJGy0ttqCCeqDc_Owp7UGB0LepciBZOUvITxDcLSjkm5wjMDQsW45O0W8FGsOE2ujE9jiuhX5OZFRhb2UGYDpwF5ggy43jrGz13GIVw7FncYIzyyoV-Xg/s320/Chevy+S10+Battery+Box+007.jpg" border="0" /></a>Unknownnoreply@blogger.com3tag:blogger.com,1999:blog-8244815155369495435.post-40940539214008497652008-08-18T21:55:00.000-07:002008-09-04T14:08:41.656-07:00Build Session 11 (3.5 hours): Rear Battery Rack Main SupportsTonight I completed the main support structure for all three rear battery racks. Next I plan to add the flat bar supports that will hold the battery boxes.<br /><br />Preparing to remove the forward cross member from the truck frame. Don't worry, the battery box support tubes will compensate for the removed cross member.<br /><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhqSGktzSdM2b95jHp_lhlJcUtz7IIuu6uGN705pXciYFSfWqIp7oFRARplScQq0BRsa3DFC1Zw7KtJ113UJq8m_n8gd0nE1O523aYz0J79leTNXOYrfvbgcHd3YLZZx2mvK540Ii-muHw/s1600-h/blog+-+Chevy+S10+Battery+Box+007.jpg"><img style="cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhqSGktzSdM2b95jHp_lhlJcUtz7IIuu6uGN705pXciYFSfWqIp7oFRARplScQq0BRsa3DFC1Zw7KtJ113UJq8m_n8gd0nE1O523aYz0J79leTNXOYrfvbgcHd3YLZZx2mvK540Ii-muHw/s320/blog+-+Chevy+S10+Battery+Box+007.jpg" alt="" id="BLOGGER_PHOTO_ID_5236106491287695106" border="0" /></a><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNza5Nw7ao9qctnoKuHS7XcRYgOSp45jYgP1Nu9XS6hn_076BjeXc-9lYHswB222snOFax52NKhqjUdCIImsms1O039TSpaDzu5Zjj1vOvGO_7SBUOMyz7ferc2NFJEQM0avwDubG4ffo/s1600-h/blog+-+Chevy+S10+Battery+Box+010.jpg"><img style="cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNza5Nw7ao9qctnoKuHS7XcRYgOSp45jYgP1Nu9XS6hn_076BjeXc-9lYHswB222snOFax52NKhqjUdCIImsms1O039TSpaDzu5Zjj1vOvGO_7SBUOMyz7ferc2NFJEQM0avwDubG4ffo/s320/blog+-+Chevy+S10+Battery+Box+010.jpg" alt="" id="BLOGGER_PHOTO_ID_5236106503224394562" border="0" /></a><br /><br />After grinding out the steel fasteners the cross member came right out. Then I was able to weld the new longitudinal battery rack supports in place.<br /><iframe allowfullscreen='allowfullscreen' webkitallowfullscreen='webkitallowfullscreen' mozallowfullscreen='mozallowfullscreen' width='320' height='266' src='https://www.blogger.com/video.g?token=AD6v5dxU2U4_QylIoAgVdUII7mr2_ubVGASWUj0zReXMQSaPW4J2ZbDyCc5BDJwuGU0zjE1rwtLZ1nuCqIxT5yTzlQ' class='b-hbp-video b-uploaded' frameborder='0'></iframe><br /><br />Cross member is out...<br /><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhzGXDIlfblK4t-WwKsFPbEOENv__MxkszRU0qlzM2oz-oKNgpKhBqhHMvByv5J6B9Nc_Cpe6QsB9C5ioQj4DLL7PM0P9XQzRrn-Z-yK8XVNZrcZa8PbFR87eBxiYpEK-WwOl4b2V0wY44/s1600-h/blog+-+Chevy+S10+Battery+Box+015.jpg"><img style="cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhzGXDIlfblK4t-WwKsFPbEOENv__MxkszRU0qlzM2oz-oKNgpKhBqhHMvByv5J6B9Nc_Cpe6QsB9C5ioQj4DLL7PM0P9XQzRrn-Z-yK8XVNZrcZa8PbFR87eBxiYpEK-WwOl4b2V0wY44/s320/blog+-+Chevy+S10+Battery+Box+015.jpg" alt="" id="BLOGGER_PHOTO_ID_5236106514170646978" border="0" /></a><br /><br />Notching the frame out to make room for the outer battery rack support tubes.<br /><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiYDrflboa-9wRdIzJL1alRefWxIBHxOa-GgQsENFDgdHmTIOL48bGupumf3H4AVz2G5p6gJATM2m9HGk-LfuGBYLOnyjfn-umRnf0YO2Eof5PVuUouSH4gGoPe9O0h_geBbeyILQ5FbIg/s1600-h/blog+-+Chevy+S10+Battery+Box+023.jpg"><img style="cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiYDrflboa-9wRdIzJL1alRefWxIBHxOa-GgQsENFDgdHmTIOL48bGupumf3H4AVz2G5p6gJATM2m9HGk-LfuGBYLOnyjfn-umRnf0YO2Eof5PVuUouSH4gGoPe9O0h_geBbeyILQ5FbIg/s320/blog+-+Chevy+S10+Battery+Box+023.jpg" alt="" id="BLOGGER_PHOTO_ID_5236106520748902210" border="0" /></a><br /><br />I cut the support tubes to fit between the new battery rack cross members.<br /><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjT77qW4oEjuAes9jLOHjtT9smtUCfEzgG64nML7TuY68rts22qiOJNfIGkjvt1EpYNGtQiE3fjXWJ0OA7idj1rMLZjorzZgITZQKAkXz4UsPiKGlo79Brl6cSjf7y_8U3wv_4idpWQtn8/s1600-h/blog+-+Chevy+S10+Battery+Box+025.jpg"><img style="cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjT77qW4oEjuAes9jLOHjtT9smtUCfEzgG64nML7TuY68rts22qiOJNfIGkjvt1EpYNGtQiE3fjXWJ0OA7idj1rMLZjorzZgITZQKAkXz4UsPiKGlo79Brl6cSjf7y_8U3wv_4idpWQtn8/s320/blog+-+Chevy+S10+Battery+Box+025.jpg" alt="" id="BLOGGER_PHOTO_ID_5236108223733678786" border="0" /></a><br /><br />Welded in place.<br /><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhxRzzdwBUq3xKibwioM0vge7lJyqLMjroqZAi5wTKy8Y1iGGbinuE0bPYMVkpN_kEluElQcwFOzE9bWCrgECuJqHd0o09cvtmL65nBPln96PbQTHxFrp6suW6Tohv-qua6RYvFmraDTXk/s1600-h/blog+-+Chevy+S10+Battery+Box+029.jpg"><img style="cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhxRzzdwBUq3xKibwioM0vge7lJyqLMjroqZAi5wTKy8Y1iGGbinuE0bPYMVkpN_kEluElQcwFOzE9bWCrgECuJqHd0o09cvtmL65nBPln96PbQTHxFrp6suW6Tohv-qua6RYvFmraDTXk/s320/blog+-+Chevy+S10+Battery+Box+029.jpg" alt="" id="BLOGGER_PHOTO_ID_5236108229750661458" border="0" /></a><br /><br />Its getting too dark to continue...its looking good though. :)<br /><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEghOyHsaP_Yd40gpLftf7JMAhSNtU9PdcgE-I6vElLteNSNuy4DqRkzuwKVFD0gJlv31ZuZpPfVePjMiSe1KcHGMO8zxvWMmYVMNr1yarvq9ZZMPpuy9cuZbj2bhM337l4IHoWLW7SvjD8/s1600-h/blog+-+Chevy+S10+Battery+Box+031.jpg"><img style="cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEghOyHsaP_Yd40gpLftf7JMAhSNtU9PdcgE-I6vElLteNSNuy4DqRkzuwKVFD0gJlv31ZuZpPfVePjMiSe1KcHGMO8zxvWMmYVMNr1yarvq9ZZMPpuy9cuZbj2bhM337l4IHoWLW7SvjD8/s320/blog+-+Chevy+S10+Battery+Box+031.jpg" alt="" id="BLOGGER_PHOTO_ID_5236108237779874834" border="0" /></a>Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-8244815155369495435.post-27884037270307218982008-08-16T23:59:00.000-07:002008-09-04T14:07:42.045-07:00Build Session 10 (3 hours): Rear Forward Battery Rack Support Structure<span style="text-decoration: underline;"></span>I spent Saturday morning building the main support of the two forward battery racks which will be located under the truck bed. It was very hot today (94F) and I did my fair share of sweating...especially while using the welder. :)<br /><br />Prepping the forward bed mounts for welding...The 4 inch Makita grinder with a wire wheel worked nicely. I love that tool.<br /><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjH1RlzUUpDbDXVX18KnkzPs2pGLbxLgiY_VdJ2iSI0ctuPA-3S6_bu8nT3Shsq23HhCjLB87tfOPbPzKVjCZiEjnm7Mfswz_Qtotlck5FoutX7aKGcitkKeenklUZ-r2Ie7bUkmMIKdSA/s1600-h/Chevy+S10+Battery+Box+001.jpg"><img style="cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjH1RlzUUpDbDXVX18KnkzPs2pGLbxLgiY_VdJ2iSI0ctuPA-3S6_bu8nT3Shsq23HhCjLB87tfOPbPzKVjCZiEjnm7Mfswz_Qtotlck5FoutX7aKGcitkKeenklUZ-r2Ie7bUkmMIKdSA/s320/Chevy+S10+Battery+Box+001.jpg" alt="" id="BLOGGER_PHOTO_ID_5235561531612732866" border="0" /></a><br /><br />After double-checking my measurements I cut a piece of 1.5 inch steel tubing and welded it between the support plates that I built during my last work session.<br /><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi1pfYTzakdgepLAGfevSmE7LSdgcReqIizT_EMCU8QlEVYg7mGPcyagGVk-Pi-qE3TYyGjhu5eJaV6OzbmwUZ4X_aKM1bHig-xB_He8VCAgFLgthHxzzf1CHefA75bXiVcKMjLswy-57k/s1600-h/Chevy+S10+Battery+Box+004.jpg"><img style="cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi1pfYTzakdgepLAGfevSmE7LSdgcReqIizT_EMCU8QlEVYg7mGPcyagGVk-Pi-qE3TYyGjhu5eJaV6OzbmwUZ4X_aKM1bHig-xB_He8VCAgFLgthHxzzf1CHefA75bXiVcKMjLswy-57k/s320/Chevy+S10+Battery+Box+004.jpg" alt="" id="BLOGGER_PHOTO_ID_5235561546161841874" border="0" /></a><br /><br />Then I secured it in place between the forward bed supports and welded it in place on both sides.<br /><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjJQ309bVSGdSQ5sLcAnMeYEV4VZ5gqmQzGiUtqe4TGC-b6vBCsrie-ROTmS2ycsKUkIGy6B9SIJaUBxWFaSGk03Ua9mtVuXhktZPpOE821QvD6YB4BPb47GIVsFBdNYVQ4OpDK8ga4A10/s1600-h/Chevy+S10+Battery+Box+005.jpg"><img style="cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjJQ309bVSGdSQ5sLcAnMeYEV4VZ5gqmQzGiUtqe4TGC-b6vBCsrie-ROTmS2ycsKUkIGy6B9SIJaUBxWFaSGk03Ua9mtVuXhktZPpOE821QvD6YB4BPb47GIVsFBdNYVQ4OpDK8ga4A10/s320/Chevy+S10+Battery+Box+005.jpg" alt="" id="BLOGGER_PHOTO_ID_5235561549523217538" border="0" /></a><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgGV-XNJAeDZEQYyMjtD6eOHJ2BrkRWCEhqKCmeQbkk17WrmJfCNZTObU4w45w1j9-yQ0Vmj5pdkK0IpOQlGBYFpELVbihDa7lJWvn6Dhpl2g1sOObJwXq0FSjOy9GkM3kKs77rq-44wR8/s1600-h/Chevy+S10+Battery+Box+009.jpg"><img style="cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgGV-XNJAeDZEQYyMjtD6eOHJ2BrkRWCEhqKCmeQbkk17WrmJfCNZTObU4w45w1j9-yQ0Vmj5pdkK0IpOQlGBYFpELVbihDa7lJWvn6Dhpl2g1sOObJwXq0FSjOy9GkM3kKs77rq-44wR8/s320/Chevy+S10+Battery+Box+009.jpg" alt="" id="BLOGGER_PHOTO_ID_5235565667349259250" border="0" /></a><br /><br />The forward support is done.<br /><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhPDbBrId6cYIYXwvufmIc-TW7ImBvCUS_jP2bnud1zY0lXy5f4X31L2YKVQMrF5cO7jenmN3Io18tvHRI7WsuonP7puQYGImxGGSUTjjGP4kTIN_LsMZhfYG31x9FfLZaav9QKMo44xdU/s1600-h/Chevy+S10+Battery+Box+010.jpg"><img style="cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhPDbBrId6cYIYXwvufmIc-TW7ImBvCUS_jP2bnud1zY0lXy5f4X31L2YKVQMrF5cO7jenmN3Io18tvHRI7WsuonP7puQYGImxGGSUTjjGP4kTIN_LsMZhfYG31x9FfLZaav9QKMo44xdU/s320/Chevy+S10+Battery+Box+010.jpg" alt="" id="BLOGGER_PHOTO_ID_5235565676786509186" border="0" /></a><br /><br />Welding in the rear support tube of the forward battery box.<br /><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj3V8_Ckkjvv7So7ZJlwpz2-ifzxuo5b5u8hJL72HYUv8RYHsjp2Jm9QSXRbQe_tOWS-maA57SUHiqWOJRnSjgHc3f1R5Ndc3KJJoPguQpZgyEmwbuyrkyQMz5oaegsYCHIJkcExds214E/s1600-h/Chevy+S10+Battery+Box+016.jpg"><img style="cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj3V8_Ckkjvv7So7ZJlwpz2-ifzxuo5b5u8hJL72HYUv8RYHsjp2Jm9QSXRbQe_tOWS-maA57SUHiqWOJRnSjgHc3f1R5Ndc3KJJoPguQpZgyEmwbuyrkyQMz5oaegsYCHIJkcExds214E/s320/Chevy+S10+Battery+Box+016.jpg" alt="" id="BLOGGER_PHOTO_ID_5235565694484255266" border="0" /></a><br /><br />The UPS guy delivered my 2/0 gauge welding cable yesterday! I'll use the welding cable to deliver the 144 volts from the traction packs (batteries) to the speed controller, motor, etc... Welding wire is quite flexible and capable of handing high voltage and amperage demands. Red for positive and black for negative.<br /><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiBPqnzHEf9jovBfGxp5Yq7b1y7eYJeOGZStOtphxQUYHKxj7YIXR-JFPyauUWnRkvmM8JHmcPyjXD_TMHsgmAfDkbxmwFVMz0aIFOmg00dOJdSh23uCUqkKJBBPwofNIFxYxvoeus5VmI/s1600-h/Chevy+S10+Battery+Box+012.jpg"><img style="cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiBPqnzHEf9jovBfGxp5Yq7b1y7eYJeOGZStOtphxQUYHKxj7YIXR-JFPyauUWnRkvmM8JHmcPyjXD_TMHsgmAfDkbxmwFVMz0aIFOmg00dOJdSh23uCUqkKJBBPwofNIFxYxvoeus5VmI/s320/Chevy+S10+Battery+Box+012.jpg" alt="" id="BLOGGER_PHOTO_ID_5235566517344338914" border="0" /></a><br /><br />That's it for this weekend. Meg and I have tickets for Batman movie at the IMAX theater and it was time to get ready to go.<br /><br />I hope to finish the "under bed" battery racks before Megan I head out for San Diego on Thursday. Stay tuned...Unknownnoreply@blogger.com1tag:blogger.com,1999:blog-8244815155369495435.post-18577727847503133392008-08-16T00:55:00.000-07:002008-09-04T13:59:26.253-07:00Build Session 9 (1.5 hours): Rear Forward Battery Rack Support PlatesI didn't have a lot of time tonight but I was determined to fabricate the forward main support plates of the front two battery racks located beneath the bed. These pieces will be used to elevated the front main support tube where the truck frame dips down.<br /><br />I had planned to used my band saw and metal blade to cut these pieces however the .25 inch carbon steel proved to robust for my patience level.<br /><br />...and so I broke out the cutting torch.<br /><br /><iframe allowfullscreen='allowfullscreen' webkitallowfullscreen='webkitallowfullscreen' mozallowfullscreen='mozallowfullscreen' width='320' height='266' src='https://www.blogger.com/video.g?token=AD6v5dx7ZN2-CxZTso9-KQFFShsQ0uV2_O6tMdYSat5XjWaocxBp9HfulnRUJNHbYHLLXLfWik6GWQtbSaOMbHmfKg' class='b-hbp-video b-uploaded' frameborder='0'></iframe><br /><br />Yes, I know, its just a little guy...not quite like the large acetylene tanks back on the farm. But it gets the job done just the same and it fits in my suburbia garage dwelling.<br /><br /><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgmrz_x54vE28pZMc3fvOUozkewSvhtCaUTglFw1WsFbQy12tcwsYG8C2JQhGbgGmHFT8W2yng9_RAv-M1BfHWZpahABt-dpmJEWeaNoe5Fh_rr3VHIfcxHkhnJy1zbyKca8bOKWiHUsPQ/s1600-h/Chevy+S10+Battery+Box+001.jpg"><img style="cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgmrz_x54vE28pZMc3fvOUozkewSvhtCaUTglFw1WsFbQy12tcwsYG8C2JQhGbgGmHFT8W2yng9_RAv-M1BfHWZpahABt-dpmJEWeaNoe5Fh_rr3VHIfcxHkhnJy1zbyKca8bOKWiHUsPQ/s320/Chevy+S10+Battery+Box+001.jpg" alt="" id="BLOGGER_PHOTO_ID_5235032248448500210" border="0" /></a><br /><br />I made a cardboard template then cut the pieces out.<br /><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgPYD8F1nTpAyrqGeg1ohhWc52JFfSb0OJgQ2gqFAi5eqdiNfvmY-C8cbmRW9y0TKJjeCPfMFjZxXkUUdQjtDMBy4qmR52nJCoQ4uBFkMmiwwOfbyDWxW3cLXAyyxo3Tu-mDl53DO7Rn6U/s1600-h/Chevy+S10+Battery+Box+003.jpg"><img style="cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgPYD8F1nTpAyrqGeg1ohhWc52JFfSb0OJgQ2gqFAi5eqdiNfvmY-C8cbmRW9y0TKJjeCPfMFjZxXkUUdQjtDMBy4qmR52nJCoQ4uBFkMmiwwOfbyDWxW3cLXAyyxo3Tu-mDl53DO7Rn6U/s320/Chevy+S10+Battery+Box+003.jpg" alt="" id="BLOGGER_PHOTO_ID_5235032962861784738" border="0" /></a><br /><br />I could have weld them in place just as they were but being the perfectionist freak that I am I was determined to grind them until both pieces were perfectly concentric.<br /><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgx6mgJtH8wUmLXkjKvu27KxG6GM0ga3Ow31cJ2C2w5sqoBfeK8o3q9pUWaONMUT9IZ4CuX94fiCWsPMUuYEif5AYf-VmVefBrGzDFuQ4PgMC9fRnxMFZtTvuWS3VfoJehCjnOom9hyphenhyphenLI8/s1600-h/Chevy+S10+Battery+Box+006.jpg"><img style="cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgx6mgJtH8wUmLXkjKvu27KxG6GM0ga3Ow31cJ2C2w5sqoBfeK8o3q9pUWaONMUT9IZ4CuX94fiCWsPMUuYEif5AYf-VmVefBrGzDFuQ4PgMC9fRnxMFZtTvuWS3VfoJehCjnOom9hyphenhyphenLI8/s320/Chevy+S10+Battery+Box+006.jpg" alt="" id="BLOGGER_PHOTO_ID_5235034015430965650" border="0" /></a><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiuvhVo8c6T5VX7pY8g6P8Wq0TPq5NCvxMwbPr31nu9NTmbBTk3m0UpaAvpaRH702lzsntZFDWuGnfHCM0BQzy-KWpWQixRcvAbDplVXPZ5zda_6plHySbsxGZZoKNlEJIVarj5l0xXvQs/s1600-h/Chevy+S10+Battery+Box+009.jpg"><img style="cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiuvhVo8c6T5VX7pY8g6P8Wq0TPq5NCvxMwbPr31nu9NTmbBTk3m0UpaAvpaRH702lzsntZFDWuGnfHCM0BQzy-KWpWQixRcvAbDplVXPZ5zda_6plHySbsxGZZoKNlEJIVarj5l0xXvQs/s320/Chevy+S10+Battery+Box+009.jpg" alt="" id="BLOGGER_PHOTO_ID_5235035168162453890" border="0" /></a><br /><br />Tomorrow I will weld one plate on each side of the frame right behind the cab. Then I'll weld a cross member support tube between them. You'll see...tomorrow.<br /><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgFIQ1R_K1v5Vc4wO5oL3BRsDz69meWPAgX8fc-vos7hcODxCUGIveSIQ2ZmF8KfePInkJP8EgpFY9BkQBnhpJd2HY258PRCzWkMrxcPfZvxqV2lfAwf-HYrC2OqrWulwwFY5San1lbsjc/s1600-h/Chevy+S10+Battery+Box+011.jpg"><img style="cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgFIQ1R_K1v5Vc4wO5oL3BRsDz69meWPAgX8fc-vos7hcODxCUGIveSIQ2ZmF8KfePInkJP8EgpFY9BkQBnhpJd2HY258PRCzWkMrxcPfZvxqV2lfAwf-HYrC2OqrWulwwFY5San1lbsjc/s320/Chevy+S10+Battery+Box+011.jpg" alt="" id="BLOGGER_PHOTO_ID_5235035175072555394" border="0" /></a>Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-8244815155369495435.post-33066589504090480312008-08-14T23:56:00.000-07:002008-09-04T13:56:38.813-07:00Build Session 8 (4 hours): Let the Battery Rack Build Session Begin...Jared and I stopped by Professional Plastics and Specialty Metals on the way home from work to pick up my order placed on Tuesday. Both businesses are located in Kent, WA within a few mile of each other. It seems like you can find just about anything fabrication related in Kent, Washington.<br /><br />Both orders were a bit pricey...it seems like steel has doubled in price since that last time I fired up my welder!<br /><br /><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhfGwW_UUbQ-stN_nje4xqsox4vJIhM8ubBF_DjWOBelD04C8lhyi9H5HViT_-zQ-22T8MAB5_fZ_R1B2NqWR4-eQ624X6GPUfAOmdtP-kTjOSxY5roSxyEBBoOWwPU22lFrgnwQt9CquA/s1600-h/S10+Battery+Boxes+001.jpg"><img style="cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhfGwW_UUbQ-stN_nje4xqsox4vJIhM8ubBF_DjWOBelD04C8lhyi9H5HViT_-zQ-22T8MAB5_fZ_R1B2NqWR4-eQ624X6GPUfAOmdtP-kTjOSxY5roSxyEBBoOWwPU22lFrgnwQt9CquA/s320/S10+Battery+Boxes+001.jpg" alt="" id="BLOGGER_PHOTO_ID_5235010723949400498" border="0" /></a><br /><br />I wasted no time as I was anxious to begin one of the installation build steps as opposed to the engine removal work. Yes, I am wearing my OSHA approved glasses, gloves, and flip flops. Actually most of this conversion thus far has been honored by the presents of my trusty old flip flops. <span style="font-size:78%;">(Don't try this at home kids...I am trained flip flop professional)</span><br /><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhccZ3bM8yrEprjINh2N4L7YIEF93L1AkhODL3MAoQCE8HdaPdlew1nTFZWr-jrQOvBvcb5lBxec93nQgXR-OL4FNCce6NlQNZBxY0vW5gEWAyJthpyKQjrKAwZqw60xCmKfE9YE3EnkIk/s1600-h/S10+Battery+Boxes+009.jpg"><img style="cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhccZ3bM8yrEprjINh2N4L7YIEF93L1AkhODL3MAoQCE8HdaPdlew1nTFZWr-jrQOvBvcb5lBxec93nQgXR-OL4FNCce6NlQNZBxY0vW5gEWAyJthpyKQjrKAwZqw60xCmKfE9YE3EnkIk/s320/S10+Battery+Boxes+009.jpg" alt="" id="BLOGGER_PHOTO_ID_5235010726745547810" border="0" /></a><br /><br />The first battery rack support is tack welded in place. I plan to complete all of the welds after most of the rack is built...just in case some of my calculations are flawed.<br /><br /><span style="font-style: italic;font-size:85%;" >I hope the neighborhood dog walkers had the forethought to bring their welding helmets with them...I would hate to damage anyones retinas as they are strolling by.</span><br /><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgb9eakL_fukY39uxC1pLa_0icE6SwgozxGEpex6S5FF_equbRB7zYjE7NzHJwEhfSEgYAz7Kd4s86hp-y1_b3WjZIIKq5QBVPZCz2DA8URhn3Qnl9_gVBkQppe0YyRKN1X0DC2x9s9td4/s1600-h/S10+Battery+Boxes+014.jpg"><img style="cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgb9eakL_fukY39uxC1pLa_0icE6SwgozxGEpex6S5FF_equbRB7zYjE7NzHJwEhfSEgYAz7Kd4s86hp-y1_b3WjZIIKq5QBVPZCz2DA8URhn3Qnl9_gVBkQppe0YyRKN1X0DC2x9s9td4/s320/S10+Battery+Boxes+014.jpg" alt="" id="BLOGGER_PHOTO_ID_5235010737228777634" border="0" /></a><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhqprHsJEs_sEe5U2f0UnjdH4Gysye1KPWjlO6hQwSmtEDExc5oe13iD_iXqrjucoHZmd-QAmFMdZjTjYoY9_jBLHVo4C251Sz2fRWIZIMmB1yN9B1C0yuXh4dx5_yvfB0qMopXU4iHot8/s1600-h/S10+Battery+Boxes+018.jpg"><img style="cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhqprHsJEs_sEe5U2f0UnjdH4Gysye1KPWjlO6hQwSmtEDExc5oe13iD_iXqrjucoHZmd-QAmFMdZjTjYoY9_jBLHVo4C251Sz2fRWIZIMmB1yN9B1C0yuXh4dx5_yvfB0qMopXU4iHot8/s320/S10+Battery+Boxes+018.jpg" alt="" id="BLOGGER_PHOTO_ID_5235010739998562210" border="0" /></a><br /><br />The second piece of 1.5 inch tubing is positioned and welded into place. Dang...its getting dark already.<br /><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEih9QVItCxkxXQNhzPHbdnB2v8m5eVFOibpqfrVP5jAsqUCFsxSDXTv7T8Dj2UeduToLnu0tBpqtXUkRYuaWdDvGK5rxvqy3ulUP5zlnL0hKJUG62oZGQweq_Yi4cx96GWxQ0MmOrY_whY/s1600-h/S10+Battery+Boxes+021.jpg"><img style="cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEih9QVItCxkxXQNhzPHbdnB2v8m5eVFOibpqfrVP5jAsqUCFsxSDXTv7T8Dj2UeduToLnu0tBpqtXUkRYuaWdDvGK5rxvqy3ulUP5zlnL0hKJUG62oZGQweq_Yi4cx96GWxQ0MmOrY_whY/s320/S10+Battery+Boxes+021.jpg" alt="" id="BLOGGER_PHOTO_ID_5235012418823214162" border="0" /></a><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg7dKFZspP2yS23t6A4l5T8WoRgsY56OVAhOEHjd3FkJ4XGvGgcyrASuMRNN921S3YHVbxA4aqSKWgrXx7e0VyT5RhSYegD8qQU7mNMjjxPTcVMf7O0SYg97TvPENdDNaeftlHHfA_AHqI/s1600-h/S10+Battery+Boxes+023.jpg"><img style="cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg7dKFZspP2yS23t6A4l5T8WoRgsY56OVAhOEHjd3FkJ4XGvGgcyrASuMRNN921S3YHVbxA4aqSKWgrXx7e0VyT5RhSYegD8qQU7mNMjjxPTcVMf7O0SYg97TvPENdDNaeftlHHfA_AHqI/s320/S10+Battery+Boxes+023.jpg" alt="" id="BLOGGER_PHOTO_ID_5235012426707391314" border="0" /></a><br /><br /><br />Once it became too dark to continue I decided to move into the garage and remove the clutch disc and take some measurements...both of which I will send to the machine shop in the morning. They will use the data and disc to mill out an adapter plate for mating my electric motor to my existing transmission. Man I wish I had a CNC mill...someday. :)<br /><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjxeN_0fiEhQ_RMLn2qIHDqVgjuYXpzLhb1r0lcUCxouqO5u6r4zf86cQvLoJ8JbzxrRQfoDFV0W6d8fkVHX9zwVvtexEVQpiFe99wQK2CEuOwdj7ncC0clroHlFFRduwkrS7gVbAT7q_A/s1600-h/S10+Battery+Boxes+027.jpg"><img style="cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjxeN_0fiEhQ_RMLn2qIHDqVgjuYXpzLhb1r0lcUCxouqO5u6r4zf86cQvLoJ8JbzxrRQfoDFV0W6d8fkVHX9zwVvtexEVQpiFe99wQK2CEuOwdj7ncC0clroHlFFRduwkrS7gVbAT7q_A/s320/S10+Battery+Boxes+027.jpg" alt="" id="BLOGGER_PHOTO_ID_5235012435046082114" border="0" /></a><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjpwb1JeijxfHGJmqUbfng_I6RSxVbESfsbKdR0kYE3GEZzViIfkcauFOgSrcUzsNPi671EhaNposs6lgjUlK5ajJ51Zc914YX3cU4Ff0d65oJQwUL0OTBpWYrYRZSkRTVxOiebcV9RjpM/s1600-h/S10+Battery+Boxes+030.jpg"><img style="cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjpwb1JeijxfHGJmqUbfng_I6RSxVbESfsbKdR0kYE3GEZzViIfkcauFOgSrcUzsNPi671EhaNposs6lgjUlK5ajJ51Zc914YX3cU4Ff0d65oJQwUL0OTBpWYrYRZSkRTVxOiebcV9RjpM/s320/S10+Battery+Boxes+030.jpg" alt="" id="BLOGGER_PHOTO_ID_5235012438908056226" border="0" /></a>Unknownnoreply@blogger.com1tag:blogger.com,1999:blog-8244815155369495435.post-19170738605813997572008-08-12T23:24:00.000-07:002008-09-04T13:54:01.442-07:00Battery Box Rack DesignTonight I planned out most of my battery layout and put together the following materials list.<br />Upon my request, Bob from <a href="http://ev-america.com">EV America</a> was kind enough to provide me with some basic battery rack plans. It looks like I will have to modify them to fit my truck year and the fact that I plan to use 24 batteries instead of 20. However, the plans are a great starting point.<br /><br />I plan to put in the order tomorrow morning. Yes, this is a little more than I need but I hate running out during a build session and I plan to use the extra on the Porsche racks.<br /><br /><span style="font-weight: bold;">Battery Racks:</span><br /><ul><li>6-10' x 2" x .25" steel flat bar for front bracing and rear U band supports </li><li>3-10' x 3" x .25" steel flat bar for rear box center and longitudinal supports<br /></li><li>4-10' x 1.5" x .125" steel square tubing for rear battery racks main suports<br /></li><li>1-1' x 1' x .25" steel plate for front of middle box bracing to frame</li><li>2-10' x 2" x .125" steel angle for engine compartment battery rack<br /></li><li>1-10' x 1" x .125" steel square tubing</li></ul><span style="font-weight: bold;">Battery Box:</span><br /><ul><li>2-8' x 4' x .25" polypropylene (white) for battery box walls<br /></li><li>1-8' x 4' x .5" polypropylene (white) for battery box lids and main control board</li></ul><br />These are the batteries that I plan to use. They are supposed to be one of the best deep cycle sealed lead batteries.<br /><a href="http://www.trojanbattery.com/Products/T-1456V.aspx">http://www.trojanbattery.com/Products/T-1456V.aspx</a><br /><br />I also ordered some POR15 ChassisCoat which is a very high quality resin based paint that I plan to use on my frame and battery racks.<br /><br />That's it for today...Unknownnoreply@blogger.com0