2006 iTech, let the mods / upgrading commence

No, I didn't even think of that approach.
I really wanted a more of a plug'n'play setup.

Jason.

 

So.
With a few more emails to Robb I have the system running.

No extra HV pack installed as yet, but it appears to be doing what it is supposed to be doing.

When the system is turned on, the contactors close and the HV fan goes to max speed.
Haven't tried driving the car with the system on as yet for what should be obvious reasons.

Now the saving starts for the new battery pack.

Jason.

 

That's kind of what I'm expecting Robb to tell me.

Now I just have to wait till I get the new pack. The wait is gonna kill me !

 

So, some more progress has been made in the last few days.
The heavy duty rear springs and new struts have been installed, and we have started on making a charger mount template.

I have also made a nice charger cooling system.
I have 2x 80cfm 12v brushless fans bolted to the charger heatsink.
And a third one will be attached behind the charger,blowing warm cabin air from the charger area to the outside vent in the rear lower quarter panel. This is also an 80cfm 12v brushless fan.

All three fans will run while the car is plugged in and charging.

Attached are the pics. I will update more once the charger is actually mounted up.

I'll be paying for the remainder of my batteries in 2 weeks.
The vendor has informed me that he has my stock ready to ship.


Jason.

 

Some more progress today.
We got the template cut out of 1.6mm galvanized steel plate and bolted into the car.
It's only bolted at the front so far. It will also have attachments at the rear, near the tail light area.
It's bolted up using rivet nuts. And 6mm bolts.

Hope to have it completed tomorrow.
It's been ridiculously hot here this week, working outside in 37 degree heat is somewhat challenging.

At the lowest edge of the plate, there will be a fan mounted pushing cabin air outside through the vent.
Still have to figure out exactly how it's going to be attached yet.

More pics will follow.

Edit. Got motivated to do more once the heat of the day went.
Got the charger bolted up and the cabin fan sitting in place.


Jason.

 

Some more effort today.
The plate has been finished and all brackets finished.
It's been test bolted into the car and is now in primer waiting for top coat.

The pics attached,show the hole cut for the cabin fan.
Also, I got the fuse holder made and painted. It's made from a short length of 40mm PVC pipe,
And two end caps. With rubber grommets where the cable enters and exits.

Not much more now till it's all bolted up and in place for the last time.

Jason.

 

It's in and done.
Looks good I think.

Might still have to trim the trim panel slightly, but I'm failrly happy with how it turned out.


The plate painted black and bolted in.


Trimming the trim (no pun intended)



Bolted in and buttoned up.

Now all that's left is the batteries and their box.
I will be paying for the remainder of the batteries tomorrow morning.

They will take at least a week to arrive, as they have to come from the other side of the country.
Once I have them, I'll contact a fab shop to get a quote for the battery box.

Jason.

 

Got motivated this afternoon to finish up the cutting of the trim panel.
Think it looks better, and it sits better too. Plus the cabin fan has less obstruction in its way too.



The remainder of the batteries have been paid for, and the vendor is planning to ship them Monday.
It will take 4-6 days for them to arrive I think.

I'll post pics once they arrive.

Jason.

 

So after much being mucked about by TNT (the delivery courier chosen by the vendor) I finally have the batteries, modules and interconnects.

I have started measuring the voltages just to make sure that they are all healthy, and so far all are within 0.001v.


10 boxes of lithium goodness

Cell modules and interconnects and nuts/bolts

Two of the 19 modules that will make the pack up.
There are 4 cells in each module.

Now all I have to do is get the battery box made up.

Jason.

 

I am now finished measuring each of the 76 cells.
Delta is 0.012v. Pretty good I think.

Jason.

 

Got a quote for the battery box today.
I'm going ahead with it and should have the box next weekend.
It will be an alloy sheet box with a 6mm lexan lid.

Pics will follow once I have the box.

Jason.

 

So the box has taken a little longer then expected, but it looks like I'll have the box finished this weekend.

I have attached a few pics the box maker sent me today.


More pics will follow hopefully this weekend.

Jason.

 

So, major progress this afternoon.
The box is made and the batteries are in the box.
Still not wired up and no polycarbonate lid as yet.
The pollycarbonate sheet that will make the lid will be 6mm thick.
I hope to have the battery box finalized this Saturday, and the final push for the last of the install the following weekend.

Pics attached.

 

Got more done today.

Pics attached.
Still have to wire up and connect the cells, and do some tidy up work.

Pretty happy with the result.

The polycarbonate lid will be covered with grey carpet once I'm done. So unless I want to show someone, it will look very much like a regular Prius hatch floor.

Cardboard template


6mm thick polycarbonate sheet lid.


Fuse and home made holder.


Fuse holder in a mount beside the box.


Sheet bolted in, but still needs some tidy up.
I plan to paint some parts to hide everything except the fan and the cells.




Hopefully it will be completed next weekend.
With the exception of the painting that is.

Jason.