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you've heard of death by a thousand cuts, well this ended up being design by a thousand cuts
after attempting to trial fit this newly augmented inverter bracket I of course realized it would now not clear the battery lid tray thingy, so I lopped a section of the left wing off (that hurt, cause I am all about symmetry) |
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second attempt, FAILED again but only by this much
I need to recalibrate my eyecrometer |
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at this point I've reached the I don't give a **** any more phase of the gentle trimming and I just went for it, and whalla a perfect fit every time !
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alright, these cables better reach
this is just a trial fit, the black plastic cable bracket is just loosely dangling on there (I didn't have the energy to deal with it that day) |
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today the stare down began between me and the first gen Chevy Volt DC DC converter, I hoped I could will it to connect itself to the BMW 530e Battery Safety Box
so this thing is like a alternator in the car, and I don't want it to have a permanent connection to the high voltage battery, so I am thinking if I tap it into the Safety Box aka the Contactor Box on the output side then it will only make a connection to the battery pack when the contactors are closed |
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maybe this will work
that may be a 20 amp fuse I may shove something lesser in there or morer I don't know, whatever you recommend I am also entertaining the idea of just shoving this entire black BMW Safety Box into one of them electrical plastic boxes and not even putting it's flimzy OEM lid back on just using the lid from the bigger electrical box, bonus if I can find an orange one fun little 4 part series on what a Safety Box is: BMW 530e Safety Box Contactor Box 1 BMW 530e Safety Box Contactor Box 2 BMW 530e Safety Box Contactor Box 3 BMW 530e Safety Box Contactor Box 4 |
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Me: gonna get a lot done in the garage this weekend
The Weather Forecast: |
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and then it was time to mount the second gen Toyota Prius electronic power assist steering brain module thingie
well the first thing I learned is that the lid comes off what kinda alian space ship mounting bracket is that ? Prius Power Steering Module EV Conversion 1 |
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then it was off to the Organic Outdoors Finesse Station, OOFS
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I must admit I was very surprised how nicely this Toyota part bolted up to the Chevy truck, only one extra hole had to be drilled in the truck frame
Note: this module originally lived inside the cab of the Prius so it is not weather proof or tightly sealed at all ! Prius Power Steering Module EV Conversion 2 |
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So the goal for this month, July 2023 A.D. (Another Deadline) is to have it run and drive !
we've been working kinda hard at lowering the bar so far to meet this important self imposed arbitrary deadline |
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could this be the final to do list?
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Only in a dream! Is there ever not a to do list?
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Still enjoying the updates on your progress. I sure hope you do a "public viewing" of the finished truck some day. I'd love to see it in person. ;)
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so I snuck out and mounted the Lexus transmission electronic "oil" pump controller to the frame this morning again using pre existing stock GM factory bolt holes? (for what I hope is the last and final time) before it got to 80°F at 8:00 am
yup, yet another OEM bracket that looks like it just fell off of the USS Enterprise, but what do I know I'm not a Star Wars fan dang it I just realized I fed those frame bolts in the wrong way, that will never pass tech, don't let Robert see that! |
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Good progress!
I don’t believe I’ve ever heard of someone using a OOFS in triple digit temps before:) |
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can you guess which grommet I needed ?
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so my local Harbor Freight claimed to have a box in stock
you can't make this stuff up folks ! |
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five stores later...
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anybody wanna 179 piece grommet set, never been raced !
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Could you please give info on the 3 hole device on page 1656? What are its functions and dimensions, etc? Thanks
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cool project, keep after it |
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Thanks, Ski
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tell me you luv wiring without telling me you love wiring
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Looks like you could use that broken Craftsman for a turn signal stalk. :lol:
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says WW Super 270 Win on it |
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but if you are in the mood for knowing a bit more about the batteries that will power this beast, I just uploaded this new video and it is pretty down to earth BMW 530e HV Battery Safety Box Control think of each battery like a 9 gallon fuel tank, and I have two of them, the MPG for EVs is guestimated using 3.5 mpg so about 30 mile range per pack, and my original plan was to run three packs for a range close to 100 miles however I have recently heard it's more like 4.5 mpg so closer to 40 miles per pack, we can only build, test, and see for ourselves |
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I don't know how you all do your wiring, but I don't do anything without my trusty hack saw
on a bit more serious note, repurposing the stock TOYOTA / Lexus OEM relay sockets is a bit of a PIA as there are 4 pin relays, 5 pin relays and umpteenth pin relays, plus some relays served multiple purposes, think rear window wiper and radiator fan type of deal so as much as I wanted to have them consolidated and nicely mounted together, I only want to use 4 pin relays that are all the same style (not rating) for the oil pump, water pump, steering motor, and eventually iBooster Why not use aftermarket sockets? Well I ordered some ( R95-160A ) but I am pretty sure they won't come with these really nice heavy duty 8 AWG wires like the stock ones do and the super wide 10mm blades |
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Nice work!
For those heavy duty relays you should get the bare terminals and the crimper to match, then you can make the connections with whatever gauge wire you want. Something like this: https://www.summitracing.com/parts/p...iABEgK03vD_BwE Here's a relay with pins https://vetco.net/products/4-pin-aut...t-high-current I can't find just the pins, but we have them at work so I know they're available. |
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thanks, sound advice, 100% on the bare terminals, and having done a few LS Swaps my collection of crimper thingies grows... and this doesn't even include the 50 Cal that lives in the garage, ha ha my only concern is the gauge ie thickness of wire the aftermarket relay sockets and terminals support, it seems like the OEM wire is as large as 8 AWG and that is the thickness of your girl friends pinky (back when she was in high school, lol) here is a properly prepped OEM four pin / four wire relay (as god intended) this one I would say only runs 10 AWG wires (hence the yellow manual calculator for reference) |
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it's always a good sign when you get to the Ignition Switch install on your build, am I right fellas?
looks like, she's seen better days has sum of that patriotic Statue of Liberty tint to her |
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meanwhile on this episode of You Can't Make This Stuff Up ! YCMTSU
OUR throttle bracket is making it's way from California to California via Texas, and you wonder why this build is taking so long, well actually it drove by my house on it's way to Texas... I'm looking at you Robert !!! did you have anything to do with this? |
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I wanted to tweak it so it would fit.
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