Build an Electric Car: Installing the Components

EVs require very few parts so installing the components is relatively simple. Below is a photo showing the major components installed in the car. As you can tell they don’t take up as much room as the engine. The rest of the space will be filled with batteries. Not shown in the photo is the compact battery charger which is mounted at the opposite side of the new motor compartment.

Ideally, the components should be placed close together to keep wire lengths short. The controller requires sufficient cooling to work properly so it should be placed in the airstream or mounted on a heatsink with a thermal joint compound for heat conduction. The potbox should be mounted on a sturdy surface and the accelerator cable should be routed in such a way so as to prevent kinks or pinching. Since there is a slight spark when the contactor closes it should be placed below the top level of the batteries. Each component should be kept away from water splash. Some EV convertors mount all their components on a board that is hinged to allow easy access to batteries and the motor.

PVC pipe is mounted under the car as a conduit for the wiring that runs to the rear battery pack. The wiring harness that runs inside the conduit includes heavy cables that connect the battery packs, a charging wire for the positive lead of the top most battery, wires for the battery box fan, and extra wires for future expansion.

To support the weight of the rear batteries, air bags are installed in the coil springs to support the weight of the rear batteries. The vent in the rear spare tire well is ventilation for the battery box. The spare tire will be stored on top of the battery box.

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Next step is installing the battery box

January 10, 2009 · Filed Under Build an Electric Car

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