The Work Begins

After repairing lights, before demolition

Pre-Demolition Work

I've finally started actually working on the conversion.  Before I could start the conversion to an EV I had to fix the existing electrical system.  The truck started and ran OK but most of the lights were inoperative.  After a bunch of troubleshooting I finally isolated the problem to the switch module on the steering column.  I removed the module, cleaned the contacts, and voila everything worked!  I no longer had to avoid taking the truck out in the evening for fear I'd be out after dusk without headlights.  I actually completed all the repairs in late June, but further works was delayed by my attendance at a conference subsequent vacation.

Demolition Phase I: Bed Removal

Bed raised off the frame

Since the battery pack is going to reside under the pickup bed, I needed to remove bed so I can fabricate and install racks to hold the batteries.  The bed was amazingly light.  Two people could easily pick it up off the frame.  According the the manual, you unbolt the bed from the frame, hook four straps to the bed and lift it with an overhead wench.  Unfortunately I lacked the wench and was working by myself.  I got a little creative raised the on 2x4s bit by bit until it was above the frame.  I did get help from my wife to move the various stanchions under the 2x4s as I lifted them up. 

Look Ma, no truck

 Then I simply drove the truck out from under the bed  as slowly lowered the bed to the ground a step at a time. I was then able to move the bed out of the garage using a dolly.  Cal-OSHA would definitely have not approved of my methods but I was kinda pleased with the creative if somewhat precarious solution.

Kinda stumpy looking without the bed

The truck looks really funny without the bed on--definitely something missing.  It's also a amazing to me how little  there is to the frame.  When I look at a car or truck it looks so big, bulky, and substantial.  But once you've pulled the body off a revealed the frame, there just so little of it there. And that's a good thing for EV conversion.  All that space between the frame members is 

Look at all that space for batteries

where most of the batteries will go.  I have to fashion a series of racks to hold the batteries so they're completely below the frame members.  I'll then replace the bed but add a hinge mechanism so I can lift the bed to get to the batteries.  Both the exhaust system and the gas tank will be removed which will open up even more space for the battery pack.

Demolition Phase II: Preparation for Removing the Engine

Engine waiting to be pulled out

With the bed removed I got to some serious demolition--removing fuel tank, radiator, exhaust system, and all the stuff connected to the engine.  It's amazing how much stuff I wont need in the converted truck.  To facilitate access to the engine compartment I removed the hood and set to work.  There's a lot more stuff connected to engines than there was in the '70s when I last worked on cars.  To get the engine out I will need that overhead wench or else I'll have to rent an engine hoist.  I also need some help to get the engine out.  My friend, Chris, is coming next weekend to help with the engine removal.  Now I just have figure out how to rig the wench.