I just went to the local plastic store where I bought a few pieces from their scrap bin. I got some 1/8" ABS sheet so that I can make a little box to cover the potbox. It's really easy to cut, using a saw or even a hobby knife. It goes together more or less permanently with ABS cement.
I previously bought some 1/2" scraps to mount the potbox on as my location was just a little tight without spacing it away from the body. Also used two layers of the same stuff to put my DC-DC on since it would have had the output ground post riding against one of the HV conduits without the extra height. Very easy to drill and provides a little isolation as well, though it will not transfer heat to the body sheet-metal. For the potbox that won't matter , for the DC-DC I have a pair of fans mounted on the heatsink, with some snap switches to turn them on in two stages, 20 deg, and 30 deg. C. On Wed, Jul 24, 2013 at 8:43 PM, Zeke Yewdall <[email protected]> wrote: > Second run of the night. 8.2 miles, going back and forth on a flatish > section of the highway (still obviously not flat, because I could go way > faster one way than the other). Goes 45mph at times :) Down 32 amphours, > so around 2kW. So, still around 250whrs/mile. There is something rubbing > in one front wheel (dragging brake maybe?) so I can probably improve that. > I haven't even checked the tire pressure, either. When I first started > out, it would pull 230 battery amps. As it warmed up, that dropped and > dropped till finally, it would only pull 80 amps from the battery. The > controller is getting quite hot -- no heat sink or fan or anything on it, > so not surprising. Battery voltage never dropped below 60 volts under > load, though the load did keep decreasing..... parked it for 30 minutes, > and it was back to being peppy, even before recharging. Looks like the > next order of business is to put a heat sink and fan on the controller. I > do have an analogue ammeter that I could put on the motor side to show > motor amps as well, if I find another shunt for it. > > I did find that the cable to the S2 terminal of the motor was loose, and > getting very very hot under the 230 battery amps (probably higher motor > amps) as in I could smell it while driving, and it was blackened around the > terminal. I need to look at it in the light and see if it got damaged -- I > tightened it back up but it was too dark to see well, and I'm not sure if > the plastic bushing melted where it goes through the motor casing. > > > > On Wed, Jul 24, 2013 at 6:28 PM, Zeke Yewdall <[email protected]> wrote: > > > Update -- got the new Elcon 1200 watt charger in, and some actual > circuit > > breakers and such, instead of just lots of wires bolted together. Got > the > > Xantrex E-xpert Pro battery monitor as well, and have some actual run > data > > now. > > > > Took it for a 4.9 mile drive, all dirt road and lots of hills both ways > > (in case it died, so I wouldn't be stuck on the highway, and it doesn't > > matter if I'm going 5mph on the dirt road up the hills). > > > > According to the monitor, I used 20AH, which at about 62 volts (what the > > batteries were sitting at most of the time under load), is 1.24 kWh, so > > around 250wh/mile from the batteries -- I don't consider that too bad for > > dealing with hills on a dirt road. Not having regen was painful > (mentally) > > -- riding the brakes all the way down a hill, then crawling up the next > one > > :) > > > > Peak amps was about 200, and batteries were sagging to about 60 volts > > under that load. Popping back up to 69 to 70 volts almost immediately > when > > load removed. On one of the steeper hills, it would not go over about > 100 > > amps -- controller (Altrax 450) was hot to the touch, and so was the > motor, > > when this happened. Battery voltage was around 62 volts under this load. > > I wonder if the Alltrax was current limiting for temp -- this was near > the > > end of the drive, and towards the beginning it seemed happy to do more > like > > 160 to 200 amps when you really pushed it. > > > > The monitor said I was down to 33% battery capacity after taking out only > > 20AH -- puekert is obviously killing me. 12 volt AGMS, and I told the > > monitor they were 80AH instead of 100AH that they claim (since they are > not > > new). http://www.npstelecom.com/pdfs/Dyn_UPS/UPS_12-370.pdf > > > > Question on the PB-6 throttle..... is it good for that to be getting wet > > all of the time... because it is, being in the old VW bug engine > > compartment in back. Rain drips right down on it. > > > > It's on the charger now, and after dinner I'll take it out for another > > spin on flatter ground (the highway) since I've got a little more faith > in > > how it runs now. > > > > Topography of the run was dropping about 440 feet over a mile, with the > > steepest section being a little over 10% grade, rising 100 feet over 3/4 > > mile, then dropping 80 feet over 3/4 mile, then turn around and run the > > opposite way. Total climbing = 620 feet vertical. > > > > Z > > > > > > > > > > > >> > >>> On Thu, May 23, 2013 at 9:43 PM, Zeke Yewdall <[email protected] > >wrote: > >>> > >>>> According to the specs, the motor is from D&D, and is 12.28" long x > >>>> 6.7" diam, and weighs 62 lbs. > >>>> > >>>> If it were me, I'd probably go with the AC-35 or AC-50 from HPEV's... > >>>> I like the specs on those, and what I've been hearing about their > >>>> performance. > >>>> > >>>> > >>>> On Thu, May 23, 2013 at 5:49 PM, Lee Hart <[email protected] > >wrote: > >>>> > >>>>> On 5/23/2013 4:18 PM, Danpatgal wrote: > >>>>> > >>>>>> Lee Hart wrote > >>>>>> > >>>>>>> Is the 6.7" series DC motor enough for this heavy of a car? > >>>>>>>> > >>>>>>> The L91 in my LeCar is more than adequate to do 70 mph. > >>>>>>> > >>>>>> > >>>>>> You don't actually go 70 in your LeCar, do you ? ;) > >>>>>> > >>>>> > >>>>> It takes a while to get up to 70 mph, but it does get there. :-) No, > I > >>>>> don't normally drive it over 55 mph, as none of the roads around > here have > >>>>> posted speed limits that high. > >>>>> > >>>>> Note that I don't have the stock Lectric Leopard Prestolite 48v > motor, > >>>>> but instead an ADC L91. I have a Curtis 1231C controller. I also had > a > >>>>> 132vdc pack at the time of the 70 mph speed run. It's at 120vdc now. > I > >>>>> haven't tried to see how fast it will go now. > >>>>> > >>>>> > >>>>> I also have the L91 in my LeCar, I've maxed out at 65 (once), and > >>>>>> with more > >>>>>> than 250 amps (at 120v) > >>>>>> > >>>>> > >>>>> Odd. Mine draws about 70 amps at 50 mph, 100 amps at 60 mph, and 150 > >>>>> amps at 70 mph. > >>>>> > >>>>> > >>>>> I've been happy with it in the small vehicle - it's no tire burner, > >>>>>> but I > >>>>>> generally keep up with traffic. > >>>>>> > >>>>> > >>>>> Same here. The L91 is no racing motor, but it is decent for an > >>>>> around-town car. > >>>>> > >>>>> For a small car like a Beetle, to get 50-60 miles range with > >>>>>> > >>>>>> lead, you've got to have 1000 lbs of lead, or MORE. > >>>>>> > >>>>> > >>>>> I'd say that's about right. John Bryan was getting that kind of range > >>>>> with his Karmann Ghia with 16 Optimas (about a 900 lbs pack), but he > was > >>>>> very good at keeping his rolling resistance low. > >>>>> > >>>>> > >>>>> To me that's not worth the weight performance hit, space > requirements, > >>>>>> hassle to keep watered, worse winter sagging, Puekert effect and > short > >>>>>> pack life, compared to lithium. > >>>>>> > >>>>> > >>>>> That may all be true to some extent. There are ways to deal with all > >>>>> these issues. However, I have gotten 15 years and three lead-acid > packs for > >>>>> less than it would have cost me for lithium. And I don't know if the > >>>>> lithiums will actually have lasted that long. > >>>>> > >>>>> I live in a small town, and lead meets my driving needs. So I'm > >>>>> content to let others go first! :-) > >>>>> > >>>>> > >>>>> If I had another $5k I'd have replaced the motor and controller and > >>>>>> put in > >>>>>> the HPEVS AC50. Perhaps in my next build (if it ever happens) or > >>>>>> upgrade > >>>>>> #2. > >>>>>> > >>>>> > >>>>> More money = more performance and better range. Each person just > >>>>> needs to decide how much he needs, and is willing to pay. > >>>>> -- > >>>>> Opportunity is missed by most people because it is dressed in > overalls > >>>>> and looks like work. -- Thomas A. Edison > >>>>> > >>>>> -- > >>>>> Lee A. Hart, http://www.sunrise-ev.com/**LeesEVs.htm< > http://www.sunrise-ev.com/LeesEVs.htm> > >>>>> ______________________________**_________________ > >>>>> UNSUBSCRIBE: http://www.evdl.org/help/**index.html#usub< > http://www.evdl.org/help/index.html#usub> > >>>>> http://lists.evdl.org/**listinfo.cgi/ev-evdl.org< > http://lists.evdl.org/listinfo.cgi/ev-evdl.org> > >>>>> For EV drag racing discussion, please use NEDRA ( > >>>>> http://groups.yahoo.com/**group/NEDRA< > http://groups.yahoo.com/group/NEDRA> > >>>>> ) > >>>>> > >>>>> > >>>> > >>> > >> > > > -------------- next part -------------- > An HTML attachment was scrubbed... > URL: < > http://lists.evdl.org/private.cgi/ev-evdl.org/attachments/20130724/02208ff2/attachment.htm > > > _______________________________________________ > UNSUBSCRIBE: http://www.evdl.org/help/index.html#usub > http://lists.evdl.org/listinfo.cgi/ev-evdl.org > For EV drag racing discussion, please use NEDRA ( > http://groups.yahoo.com/group/NEDRA) > > -------------- next part -------------- An HTML attachment was scrubbed... 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