Gav's EV Conversion 13 - The Control Panel

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With the racks installed and out of the way I was able to create and install the "Control Box" and Curtis 1231C Controller.

I started by 'Tetrising' all the components into a metal box I found, and screwed everything down.
After that I installed the Controller onto a nice thick plate of aluminium to help remove any heat as apparently they can get hot at times. Then it was a matter of bolting it all down and pre-wiring everything ready for the batteries.
I even installed the cool Kill-Switch with a choke cable from an old Mini!

Progress is roaring along. My batteries have been ordered and should be installed within a fortnight with luck.
The ETA for completion is most likely January-ish!

Watch this space!

Category:

Autos & Vehicles

Tags:

• Gav's
• Electric
• Car
• Vehicle
• Conversion
• New
• Plymouth
• Zealand
• Step
• 13
• Control
• Shelf
• Controller

[cant7think7clearly]

I took it up the road and back three times (about 3km) with the controller only getting warm. 3km is our average drive distance here too so I'm not too worried in this instance. The next EV I create will probably be a longer distance driver so I'll go the extra mile for that one with heatsinks galore.

[cant7think7clearly]

Thanks guys! I never even thought of using grease. That will save me the embarrassment of buying cheap lipstick again. Good thinking! :)

The High pedal lockout is apparently built into the controller so we were worrying for nothing!

Good for you Gregishere, I hope you get a donor car soon! The price of gas is getting crazy now!

Annnnd the next video is being uploaded as I type this!! :)

[cant7think7clearly]

Thanks mate! I hope you get a donor car and have a go with your own EV too! :)

(And hats off to Altavista's "Babelfish" site which allowed me to translate the comment!)

[Berkut13]

Gav, I love what you are doing...BUT...dude, you soooo need to spend a few bucks on a proper wire crimping tool. I've built an airplane and the proper tools can make all the difference! Best of luck and I can't wait ot see this thing drive around!

[cant7think7clearly]

Roger that, I'll try find a proper crimper and re-crimp those mini lugs. As for the huge main cable, I'm having someone do that for me :)

[cant7think7clearly]

Sure thing mate! There'll be a huge re-cap at the end of the series going over all the little things like the vacuum pump in action, flashing recharging light, turbo timer etc etc etc.

Still have a bit to do yet, once the batteries are in it'll be time to build my sealed rear battery box. It never ends... :)

[stonerace19]

Great lipstick trick Gav. I've actually done the same thing in the past using other things.

[mszmarcin]

name of song?

[spokehedz]

4:30 - Yeesh... Get the dang power cable out of your work area. XD

[greenboy623]

My g-d mate, that motor rev sounds beautiful!

[lazzer408]

I understand what your saying but I think he might need a bit more info then that.

[TommeyLeeReed]

The best way is to read the ground and m- with a comparator, this can read when the mosfet/ibgt are open all the way when the volts go from 144v to 0v, 0v is when motor is fully on. The compartor shut off main power relay. This works very well!

[kc7ekk]

I am building my own controller right now. How did you solve the problem when your power IGBTs/MOSFETS go south and you are stuck with a full on transistor(s) that has no intention of obeying the control of the PWM circuit? What kind of emergency stop circuit do you use?

[TommeyLeeReed]

Save money, and build your own high power speed controller!

[goku1940]

How far WILL you travel with this car once finished?

[flatpicker1234]

Do you have any place I can go to and get the wiring Doc's or Does that come with the control panel ? Do you have a list of parts used and suppliers ?