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Difference between revisions of "User:Cewert"

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(Initial User page.)
 
(Added my photos)
 
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I am converting my '04 Prius via the CalCars [[PriusPlus]] method.
 
I am converting my '04 Prius via the CalCars [[PriusPlus]] method.
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====Photos from Chris Ewert's Conversion====
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<gallery>
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Image:Cutting Aluminum.JPG|Cutting the aluminum with a hacksaw
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Image:Tray Pieces.JPG|All the pieces necessary for the battery trays
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Image:Tray Parts Laid Out.JPG|All the parts from the tray laid out
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Image:Tray Set Together With Battery.JPG|Battery tray just set together
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Image:Tray Set Together Close Up.JPG|Close up of the battery tray just set together
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Image:Tray Ready for Jig.JPG|Tray set together, ready for creating "jig"
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Image:Making Tray Jig Step 1.JPG|Starting to assemble the jig
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Image:Making Tray Jig Step 2.JPG|More assembling the jig
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Image:Making Tray Jig Step 3.JPG|Getting the jig assembled
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Image:Almost Finished Tray Jig.JPG|Mostly finished tray jig
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Image:Dremel Drill Press.JPG|Dremel drill press used for drilling holes in angle irons
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Image:Holes drilled in aluminum.JPG|Holes drilled in the aluminum, then countersunk
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Image:Closeup of Sample Finished Corner.JPG|Sample corner finished (done on scrap aluminum)
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Image:Screws Sticking Through Partially Assembled Tray.JPG|Shows the self threading screws sticking out
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Image:Finished Tray.JPG|The finished tray
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Image:4 Finished Trays.JPG|All 4 finished trays laid out like they will be
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Image:2 Trays with Some Supports.JPG|Experimenting with the support angle irons
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Image:Starting on the Top of Battery Box.JPG|Starting on the top of the battery box
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Image:Top Battery Box 45 Degree Cuts.JPG|45 degree angles cut in angle irons
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Image:Top Battery Box With Corner Bracket.JPG|Corner bracket just set on the top
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Image:Batt Box Top 3 Angles.JPG|3 angle irons cut and just sitting on the box
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Image:Plexiglass Shield.JPG|Shows the Plexiglass "shield" on the inside of the angle irons
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Image:Batt Box with Bolt Down Angle.JPG|Partially assembled battery box - bolted on top, but not the sides
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Image:Inside Corner.JPG|Inside of the corner of the battery box top
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Image:Binding Posts Ground Down.JPG|Binding posts that I choose to use.  They worked, but they aren't part of the official conversion method
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Image:Finished Corner.JPG|A completed corner, bolts in and have been ground off.
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Image:Batt Box with Bolt Down Angle.JPG|Shows the angle iron that will be used to bolt down the top
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Image:Mostly Finished Batt Box.JPG|Mostly finished battery box.  Still lacking the bolts in the center of the pack, holes for bolting the top down and holes in the frame
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Image:Fuses and Holders.JPG|Fuses and holders
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Image:Fuse in holder.JPG|A fuse in it's holder
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Image:Bottom of JTN60060.JPG|Bottom of the fuse holder (for DIN rail mounting)
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Image:EV200 Contactor.JPG|The Kilovac EV200 contactor
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Image:P1240040.JPG|Battery Box sitting on steel tube
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Image:Batt_Box_with_screw_lift_supports.JPG|Battery box sitting on steel tube with second tube for screw lift support
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Image:Bracket_on_OEM_Batt_screw.JPG|Alt mounting method: modified hanger bolted into battery box mount
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Image:Batt_box_test_fit_forward_design.JPG|Alt mounting method: Test fit of unfinished battery box top in forward location
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Image:Charger_in_tirewell.JPG|Charger in tirewell
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Image:Welded_angle_iron_1.jpg|Welded support connected to support angle irons
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Image:Welded_angle_iron_2.jpg|Welded support connected to support angle irons
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Image:Alt_method_support_angle_irons.jpg|Support angle irons
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Image:Right_side _battery_box_supports_alt_method.jpg|Right side battery box supports
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Image:Left_side_battery_box_supports_alt_method.jpg|Left side battery box supports
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Image:Rubber on center batt box support.jpg|Rubber pad under support angle irons
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Image:Entire alt batt box mounting supports.jpg|Entire battery box mounting supports
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Image:Electronics box being assembled.jpg|Electronics box being assembled
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Image:Electronics Box Partial 1.jpg|Mostly completed electronics box
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Image:Electronics Box Partial 2.jpg|Mostly completed electronics box
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Image:Electronics Box And Charger in Tire Well.jpg|Installed electronics box and charger
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Image:Electronics Box And Charger in Tire Well 2.jpg|Installed electronics box with top on
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Image:HVD1 in electronics box.jpg|Close up of HVD1 installed
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Image:Contactors in electronics box.jpg|Close up of contactors installed
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Image:Left side of electronics box.jpg|Left side of electronics box
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Image:Right side of electronics box.jpg|Right side of electronics box
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Image:Fuses in electronics box.jpg|Close up of fuses in electronics box
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Image:Zivan NG3 Charger connected.jpg|Close up of ZiVan NG3 charger
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Image:PriusPlus control board unstuffed front.jpg|Unstuffed control board - front
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Image:PriusPlus control board unstuffed back.jpg|Unstuffed control board - back
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Image:Batteries being installed 1.jpg|Batteries being installed
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Image:Batteries being installed 2.jpg|More batteries
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Image:Batt box top modified for alt mounting method.jpg|Battery box top (modified for alt. mounting)
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Image:OEM Battery Hold Down Screw.jpg|Bolt on top of OEM battery
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Image:Removing carpeting from top of OEM battery.jpg|Removing carpeting from on top of OEM battery
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Image:Removing rear drivers side seat top.jpg|Removing the upright part of the rear seat
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Image:OEM battery exposed.jpg|The OEM battery exposed
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Image:Opening OEM battery.jpg|Opening the OEM battery lid
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Image:Inside OEM battery from back of car.jpg|Inside the OEM battery (unmodified) from rear of car
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Image:Inside OEM battery after tie in.jpg|Inside the OEM battery after HV tie-in
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Image:Low voltage wiring inside OEM Battery.jpg|Unmodified OEM battery low voltage wiring
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Image:Low voltage wiring inside OEM Battery modified.jpg|Modified OEM battery low voltage wiring (for charge interlock)
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</gallery>

Latest revision as of 03:14, 27 April 2007

I am converting my '04 Prius via the CalCars PriusPlus method.

Photos from Chris Ewert's Conversion

  • Cutting the aluminum with a hacksaw

  • All the pieces necessary for the battery trays

  • All the parts from the tray laid out

  • Battery tray just set together

  • Close up of the battery tray just set together

  • Tray set together, ready for creating "jig"

  • Starting to assemble the jig

  • More assembling the jig

  • Getting the jig assembled

  • Mostly finished tray jig

  • Dremel drill press used for drilling holes in angle irons

  • Holes drilled in the aluminum, then countersunk

  • Sample corner finished (done on scrap aluminum)

  • Shows the self threading screws sticking out

  • The finished tray

  • All 4 finished trays laid out like they will be

  • Experimenting with the support angle irons

  • Starting on the top of the battery box

  • 45 degree angles cut in angle irons

  • Corner bracket just set on the top

  • 3 angle irons cut and just sitting on the box

  • Shows the Plexiglass "shield" on the inside of the angle irons

  • Partially assembled battery box - bolted on top, but not the sides

  • Inside of the corner of the battery box top

  • Binding posts that I choose to use. They worked, but they aren't part of the official conversion method

  • A completed corner, bolts in and have been ground off.

  • Shows the angle iron that will be used to bolt down the top

  • Mostly finished battery box. Still lacking the bolts in the center of the pack, holes for bolting the top down and holes in the frame

  • Fuses and holders

  • A fuse in it's holder

  • Bottom of the fuse holder (for DIN rail mounting)

  • The Kilovac EV200 contactor

  • Battery Box sitting on steel tube

  • Battery box sitting on steel tube with second tube for screw lift support

  • Alt mounting method: modified hanger bolted into battery box mount

  • Alt mounting method: Test fit of unfinished battery box top in forward location

  • Charger in tirewell

  • Welded support connected to support angle irons

  • Welded support connected to support angle irons

  • Support angle irons

  • Right side battery box supports

  • Left side battery box supports

  • Rubber pad under support angle irons

  • Entire battery box mounting supports

  • Electronics box being assembled

  • Mostly completed electronics box

  • Mostly completed electronics box

  • Installed electronics box and charger

  • Installed electronics box with top on

  • Close up of HVD1 installed

  • Close up of contactors installed

  • Left side of electronics box

  • Right side of electronics box

  • Close up of fuses in electronics box

  • Close up of ZiVan NG3 charger

  • Unstuffed control board - front

  • Unstuffed control board - back

  • Batteries being installed

  • More batteries

  • Battery box top (modified for alt. mounting)

  • Bolt on top of OEM battery

  • Removing carpeting from on top of OEM battery

  • Removing the upright part of the rear seat

  • The OEM battery exposed

  • Opening the OEM battery lid

  • Inside the OEM battery (unmodified) from rear of car

  • Inside the OEM battery after HV tie-in

  • Unmodified OEM battery low voltage wiring

  • Modified OEM battery low voltage wiring (for charge interlock)

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