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Post by vmrod on Nov 20, 2011 22:56:46 GMT -3
Just a quick stop to let folks know that I was not kidnapped, nor did I die. Since the local Rennaissance festival is going on, I'm busy with that. I am in the process of ordering an accelerator cable, and found a great location for the e-pedal. I'll post more when I actually do some car work.
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Post by vmrod on Dec 7, 2011 8:09:38 GMT -3
The new accelerator cable works much, much better. I need to firmly bolt down the e-pedal (temporarily held in place now), then rewire the pedal to the controller. Not much left to do before a test drive. (or not much hard stuff)
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Post by carlnelson on Dec 11, 2011 13:58:55 GMT -3
Thank goodness!! I was just going to come here and beg for a end of year update!!! Way to go on the progress and can't wait to see pictures!!
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Post by vmrod on Dec 13, 2011 8:09:05 GMT -3
You are in luck. The local Ren-faire is over, and I'll take time off work during the holidays. I'll also have my son around for help.
This means, I might just be able to go for a test drive before year's end.
I didn't order the brake stuff, yet. So, the brakes will not be good. But, this never slowed testing before. (ha! Kinda a funny there.)
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Post by carlnelson on Dec 18, 2011 0:48:28 GMT -3
Nice, nothing like sharing a project!!
I look forward to seeing this running! I love the Opel, ever since I saw it on Mother Earth News as the Hybrid Electric car... I bought the plans but they still sit some 30 years later... lol Brakes are some what over rated... if your careful!!! I'll check back in later!! Enjoy!!
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Post by vmrod on Jan 3, 2012 0:08:26 GMT -3
The holiday break was great! Just what was needed.
1. There are (9) 12-volt/control system wires left to terminate!
2. The DC-DC converter needs the (2) power leads terminated.
3. Batteries need to be installed, and the (2) power leads connected.
4. The charger needs to be installed and (2) output leads connected.
5. Install E-meter instrument in car.
6. Rehookup speedo and clutch cable.
7. Test drive!!!!
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Post by carlnelson on Jan 4, 2012 19:20:44 GMT -3
Nice! looking forward to pics and the description of the driving experiance!!! lol Happy New Year to you!!
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Post by vmrod on Jan 9, 2012 11:37:40 GMT -3
Pics are finally here! First the gab.... The speedo and clutch cable were installed. Clutch spring still needs installation (easy). A bolt was added to the rear-end as needed. The stick shift reverse lockout mechanism need to be put back together now. The EV-display got mounted in the vehicle (made a bracket). Only the ground wire (easy) and communication cable needs to get installed. The charging relay box was totally wired up, and the wire routing got cleaned up a bit. I'll be ordering a few connection components soon. (for DC-DC convertor input power). The main charger and batteries will get installed next. Wow!! Getting close! Still need to install the tubing for the Zilla cooling system. All other components are in place. Notice all the little red switches? (There a rotary switch in the middle too.) The switches allow me to configure the system without having to rewire things. As an example, I can shut the DC-DC convertor off, only have it on when the key is on, always have it on, or have it on only when charging. 1 switch gives me the option to output either 14.2V or 13.6 from the DC-DC convertor, but only when the main pack is charging. 1 switch allows the main battery pack to charge fully to 205V or to use the setpoint in the EV-Display (190-195V). I need to use the lower setpoint right now, because my Lifetech batteries do not balance like one would expect. Once I have a proper BMS, I can flip a switch and charge to 205V. (After charging, the voltage settle down to 188V) 1 switch gives the option to either have 12V power to the Zilla all the time, or only when the ignition is on. Another switch will turn off my 12V accesory battery. Great for working on the car! Another switch will allow me to switch amps or motor speed inside the car's gauges. (This is the only switch not wired, but will get done sometime). In the foreground, you can see the E-accelerator pedal. I used a cable to interface with the existing pedal assembly.
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Post by vmrod on Jan 16, 2012 0:09:25 GMT -3
The traction pack battery charger has been installed! The 'enable' wires were connected to the appropriate connections in the car. This means I have (3) 12v wires left to connect. (2 are ground wires.)
The e-pedal wiring was rerouted into the main harness. Since all control wiring (under-hood) had been routed, I taped up and secured the wire loom. Man, it's looking good.
I reinstalled the rear speakers and deck, so it looks complete again. Half of the testing batteries are in place now (but not wired yet).
I've got a little wire clean-up to do under the dash, then re-install the radio. Not much more! Can't forget the reverse lockout reconnect!
After all the prior stuff is completed, then the high voltage wiring will get run. Then a road trip! (video will be made.)
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Post by vmrod on Jan 22, 2012 10:54:33 GMT -3
Interior fuse box pushed back into place and secured. Dash re-secured. Re-installed radio.
Have 2 under-dash wires to tape and label. (for future use). Maybe the e-pedal can get bolted down properly. Perhaps the Zillas cooling system tubed-up. All do-able today.
I'm waiting on some high voltage standoffs before wiring that up. I may scout the routing out a bit. Not quite sure how it will go.
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Post by carlnelson on Jan 30, 2012 16:22:55 GMT -3
Nice progress!! Sounds soooooo close to driving!! Good going!!
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Post by vmrod on Feb 13, 2012 19:49:00 GMT -3
I'm ok over here. Just been either busy, or too cold outside for e-car work. It will warm up soon, though.
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Post by carlnelson on Feb 24, 2012 22:53:25 GMT -3
We (I) can't wait!! lol But understand! I'm in the middle of buying a new place, where I live now is .96 acre, the new place 5 acres, more space for me to build a shop!!! Hopefully by spring (in Alaska end of June) I'll be in our new place and have the old one for sale.... The new place is 40'x32' and the entire downstairs is garage, upstairs living! Heated garage floors too!! Later!!
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Post by vmrod on Feb 27, 2012 18:26:49 GMT -3
Wow! Sounds like a dynamite shop! Having my car outside really slows the progress.
We have rain forecasted until Friday, and it may carry over to the weekend too.
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Post by vmrod on Mar 19, 2012 11:01:22 GMT -3
;D ;D ;D Getting VERY, VERY close! The DC-DC convertor (power input) still needs to be tied into the high voltage system, and the main traction battery pack charger needs to get tied into the system too. The few items that are left are very small, and not difficult to install. This past weekend, with the help of my wife, the high voltage cables were routed from the batteries (sitting in rear deck of car) to the proper locations in the engine compartment. The ignition key was turned all the way on....precharge on....click goes the main contactor!!! AS soon as the key is relaxed to the 'run' position, click, and the main contactor opens. No more high voltage power. I try again, this time I just hold the key in the 'start' position. The main contactor closes and stays closed. The pedal is pressed and the motor starts whizzing!!! The tachometer is displaying the motor speed or amps (as I forgot what I set the Zilla to output). Nice to see a gauge functioning! Things feel smooth in nuetral. I cannot drive the car while holding the key, so I have to resolve this issue. I think I mistakenly swapped the key input and start input wires on the Zilla. This will be an easy issue to identify with my meter, and very easy to fix. Hopefully next Sunday, the first video will be made of the Opel venturing out in the neighborhood!
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