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User:Cewert

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Revision as of 03:14, 27 April 2007 by Cewert (talk | contribs) (Added my photos)
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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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