|Rear battery pack cabling complete|
|Working with 2-0 cable|
|Motor controller & DC-DC converter|
With the rear battery pack jumpers done and the main lines run to the front I tackled the under-the-hood wiring. I wanted a breaker on the main line so it was easy to disconnect the power to work on the components. This turned out to be a non-trivial exercise, again due to the difficulty of working with 2-0 cabling. I was able to fabricate a bracket to hold the breaker out of 16 gauge sheet metal. I found a nice plastic box to enclose the breaker at my local surplus store. Not sure of it's original purpose, but it makes a decent electrical box. Again I had to make a bunch of short 2-0 cable jumpers to complete all the high voltage wiring under the hood.
With the high voltage cabling done, I moved on to running all the low voltage (12v) control wiring. This was much easier, but still tedious.
Oh what a tangled web we weave
|Legacy 12v wiring harness|
The last wiring task is to hook up the battery management system (BMS). This requires installing small circuit board on each battery cell and then wiring them into the BMS. The circuit boards on the cells measure the voltage of each individual cell and can shunt the charge voltage around the cell once it's fully charger. The BMS keeps track of the state of charge of every cell and controls the operation of the battery charger.
We'll I'm now going on 6 weeks behind schedule. I'm thinking I might make a Thanksgiving completion date.