Completed wiring, positioned all batteries, and fired up the complete system…. *GIGGLE* *HEHEHE*
High voltage cables on controller
Motor and controller connected and ready to go
Battery wiring setup
Circuit breaker bracket in position
Dash mounting test of main gauges
The bus getting some elevation
Inspection of the brake servo
Cool under bus shot of complete drive train
Front trays completed, Billie and Mike added threaded rod and bar across the top to hold the batteries down – lookin’ nice! Completed heat shrink and battery boot assembly for battery interconnects. Located fuse and master breaker, completed front battery tray interconnect cable.
Back tray completed, ready to be bolted.
Motor mount wrapped, weld, grind, weld, grind, weld, grind, etc and primed.
Reassembled mount onto motor, shaft key inserted and fixed to coupler.
Lightened flywheel bolted on, clutch reassembled (nice German made – quality stuff…).
Transmission resealed and complete.
Attached mount to motor, transmission to mount, support bar to rear of motor and then the whole package was mounted for final assembly to the bus.
Brought heat gun and heat shrink (from Frys) to finish battery cables, heat gun lasted 3 cables and then stopped working!
Decided to reuse the radio slot for the three main meters: 80-180v (Main Pack), 0-1000A (Main Pack), 6-16v (Aux Battery). Brought a very nice trim piece from Bus Boys in CA, can get these to fit without major modification to radio slot.
Started making first battery and motor cables – needs some heatsink to make these nice and tight.
Hammer crimper is crude but very effective!
Cable arrived from Revolt
10ft of 4/0
50ft of 2/0
It’s all bright orange!
Damn Volkswagen’s – even with an electric motor they still leak oil!
Motor mounting plates assembled, basic alignment completed.
Connected flywheel (lightened… I might add, very nice), clutch kit and ran on bench with transmission:
Motor – Motor coupler – Transmission mounting:
Rear battery rack:
Controller panel in place:
New drive shafts:
