Zero emission inspection… met with James Udi from GEFA.

Vacuum pump wired up – only temporary wiring will clean up and do it nicely.

Found major air leak from hose connected to the servo, replaced and now it sucks correctly and stops very well!

Disaster! – While tightening the nuts on the Main Contactor the stud twisted off, M8 is big, but copper is soft… and I guess I’m stronger than I think!

Good news – I designed my system with a certain degree of redundancy in this regard, I added the second contactor for protection and so in an emergency I could bypass or swap the defective contactor and still drive it. So thats what I did. Bypassed it.

First major outing, took StealthBus from Cumming, GA to Lawrenceville, GA – 26 miles in total.

Starting pack voltage 154v, finish 143v (pretty close to 80% DOD).

Plugged in for full charge, 5hrs at 13A from wall plug the pack back up to 160v – cutoff set at 172.8v (per specs).

Need to hook up a 30A 220V circuit to the garage, so I can charge faster, but 115A/15A ok for now.

Controller board – now available in aluminum!

Disassembled the MDF prototype and cut and drill the aluminum mounting board and reassembled.

Tags & Insurance – the StealthBus is ready for the highways. Have a regular style tag, and an appointment booked for early Monday for the inspection to get the special AFV tag.

Many thanks to my wonderful wife Mindy for the hard work on the legal side and getting all the paperwork in order.

Fixed the passenger side turn signal and brake lights – bad lamps easy fix.

Connected the monster charger and gave the pack it’s first charge.

Cool picture of the borg like charger lit up..

The ~PCF-30 is very easy to use and setup, I am very impressed with this charger.

Some battery math to get it set right:

|!State|!Per Battery|!Total|

|Equalization|14.4v|172.8v|

|Full charge|12.8v|153.6v|

|~50%|11.8v|141.6v|

|No charge|10.5|126v|