Insulation

Feeling paranoid that I am placing batteries in metal cases I have decided to insulate the inside of all the metal boxes. Even though the voltage cable connection points are covered with rubber boots and no metal is exposed the inside of the controller (pictured) has been coated with heat resistant high temperature polyimide tape…

Power cable–ing

Spent some time power cable–ing. I have managed to route the 12v, hall sensor cables, and power cables after making a new gland bracket to hold the V/W/U motor cables. Need to do some tests before firing it up. The last test used 48v on the connector. It should use 12v, technically, so I will…

Wiring (interim)

Have finally started the wiring and installation. Realistically I need to make sure all is working in situe before going for a final installation and metalwork treatment. Progress is slow due to time restraints, but happening. My main concern is ensuring I make the correct connections first time to avoid damage to components and to…

1st charge

Uprated the cables to 35mm2 to start testing the battery. In this first charge I pushed the state of charge (SOC) from 25% to 50%, took about 1hrs 13mins. Indicates that a full charge may be just under 5hrs. Also using this 25% charge suggests a 100AH full capacity. In general, happy charging is working….

BMS Installation

Have finally got around to firing up the BMS. After a couple of cell step voltage checks (that were surprisingly close; 0.016 cell diff). I was eager to look out for mis-wiring and errors but luckily found none. Awesome. Turned on the ANT BMS which seems to have been tricky in past versions of the…

Top panel breaks

I have started to think about how to supports and breaks on the top panels in 300mm chunks. Although I’m still at very early days I thought it will be sensible to make the controller cover made from aluminium the main structural component of this assembly. The top, side, front and rear replacement panel pinning…

282 LEDs

After experimenting with a regular domestic light to check out the effect of back lighting the translucent red filament I managed to get my hands on some 12v LED strips to see what they look like. I worried that the light might either be too bright or dull, but this was not an issue. The…

Bit more rear red?

Have been experimenting with translucent materials and thinking of 101 ways to drain the battery while I wait for parts to arrive. Decided to have a go at an ambient/stop night time light. As the only colour I believe I should use on the vehicle at night are front: clear/amber and rear: red/amber I thought…

Cover redesign

3 issues that seem important at the moment: Access to the control panel – Currently thinking of a hatch over the control panel that hinges from the front (pivot point arrowed in red). Potentially this could be locked. Air flow to the bottom of the controller – Marked in green thinking that it would be…

Switch panel

Need to start mounting some of the components that are just hanging around at the moment. I have put something together in CAD quickly and spent a bit of time with the printer. Have tried a new material rPETG that has a substantially higher temperature and water resistance and has excellent ductile strength making it…