Updated - The gearbox will stay / Go.

I now have a better VFD and have a 5.125 ratio diff so I will no longer need the gearbox!

[I made a design decision that the gearbox will stay in the build unless I can get a more powerful motor controller. ]

I don't think the one I have will provide sufficient power for a standing start.

Gas less MIG: I am thinking of buying a Gas less MIG welder to do my own welding. I will have to be sure this is allowed by the engineering inspector.

Aerodynamics and LRR tyres

Here ares some nice pages regarding ute aerodynamics and Low Rolling Resistance tyres from Greenseal and SJEAA.

Better Vacuum Pump

After spotting a post on the AEVA forum I bought a different style vacuum pump. This seems to be a rotary vane type. It may be able to be connected to the brake light switch via a relay which will simplify the build a bit. It sis lighter and seems quieter.

Update

I haven't posted for a few weeks. I took my family on holidays to rainy Queensland for 2 weeks and I haven't done much more EV purchasing.

I do have the contactors ordered from ZEVA and I have ordered a different brake vacuum pump from eBay.

The next critical step in the project is to buy a vehicle. Most people buy the vehicle first, then design around it. I am do it the other way around. Mostly because of my technology choices. (AC). I have been checking tradingpost.com.au and drive.com.au every Thursday for a 2 week drive, 89-95 Extra Cab, Toyota Hilux.

I have also bought some 12 volt kettles to use the elements and a pump for a water heater. Construction photos to follow.

In the last week I have enquired about ZEBRA batteries from MES-DEA. They said they 'usually' only supply to OEMs so I asked for pricing anyway. These are fantastic batteries. I only hope that they will allow me to purchase one.

If you are reading this and you are in Australia, I strongly recommend you check out www.aeva.asn.au/forums This is a great source of information on conversions.

Speed controller arrived today from WA

My Danfoss VLT6042 arrived today.

It is in an IP54 case so it is splash proof. This is the best considering it will be under the bonnet. The penalty is that it weighs an extra 20Kg above the IP20 model.

I removed the fan unit from the top as it will be cooled from the heatsink on the back.

All going well it will be just short enough to fit between the front guards of the yet to be purchased Extra Cab Hilux. With the fan removed it is 820mm. The guard width is 900mm.

I ran it up on 230V and it can be programed from the keypad. I am having trouble getting the RS485 computer connection working. I will have to buy a different RS485 converter I think.

Circuit Breaker, Cable and Chargers

Some friends of mine (Thanks Tim and Bruce) were dismantling a 30kVA UPS and scrounged a few parts for me.

Circuit Breakers. The large unit is rated at 250VDC, but has a micro switch that I will use to release the contactors if triggered. This should perform adequately with only a few milliseconds of 300+ volts.

The 50 amp units will be used on my 2 x 25A 12 volt supplies.

16mm2 cable (overkill but will work very well)

I bought 13 x 48 volt / 2.5 amp SLA chargers from e-Crazyman (eBay)

They are fairly large, but quite light. They are fan cooled and are 2 stage.

I also received an RS232 to RS485 adapter, also from ebay, so I can 'talk' to the Danfoss 6042 drive when it arrives on Monday.

Things are progressing, but there is a long way to go.

I am amping to finally get a vehicle.

Heater / Air Conditioning Idea

My friend Iain had an interesting idea that I will pursue.

That is to modify the air conditioning to be reverse cycle.

The idea would be to use the valving and capillary tube from a reverse cycle air conditioner (perhaps an in window unit from the council cleanup) and integrate into the vehicle heat exchangers.

The standard automotive compressor would be driven from a small 3 phase motor. This will need another VFD (Variable Frequency Drive) but on a much smaller scale than the traction unit.

I will be looking out for a jucked aircon unit. I have an old 1/4 hp 3 phase motor from the factory at work that has recently been dismantled.

This will make an interesting side experiment.

If this fails I will use the idea from Trev for a heater and do away with the aircon.

Vehicles - 2 door Extra Cab Hilux.

I have been researching more vehicles in recent weeks as I wait for various parts to arrive.

I have narrowed my search down to a 2 wheel drive 89+ Hilux Extra Cab. The reason for the change from a van is:
a. It is tricky to find a van in good condition from the late 80's
b. My battery budget was underestimated due to peukert effect

I needed to find a vehicle with a higher GVM and still a 4 seater.

After looking at dual cab Hiluxes I found that the tray was too far back and would upset the balance of the vehicle too much. At the yard, I spied an extra cab which is a 2 door but with back seats with minimal leg room. Perfect for the kids.

I will need to swap the power steering box for a manual unit to avoid having to power the PS pump.

Pot Box arrived

The curtis Pot Box arrived today from Mylong Industries in Sydney.

The good news is that the pot travels 40 degrees and the resistance is 5k across the end terminals of the pot. This means it can be used as per the schematic on the VFD.

This is like Christmas every few days with new parts arriving :)

Unfortunately it didn't have the little brass cable clamp on it. I will check with Bylong.

Brake booster vacuum Pump ordered.

I have ordered my vacuum pump from eBay $100 + 50 postage. If you are searching, look for the part number 107CDC20 (worldwide and include description). It is also known as 12 VDC Thomas Diaphragm Vacuum Compressor Pump . As a bonus it includes the gauge and in the eBay ad, it pictures a vacuum cylinder. I will need to order the vacuum switch separately.