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There are three of these rack mounts (primed angle) on the main frame. Two near the transmisson (one on each side) and one near the front on right frame (shown). This was a bit of tricky welding (sparks falling on me). Always have a second person nearby during these tricky operations with instructions and safety equipment. |
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Left the inital pieces long so I could mark the length. Looks pretty weird! |
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A board set the hood line for the top of the rack. |
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Every bracket part had to be cleaned, primed and painted. Shown are breaker, vacuum tank, and throttle brackets. I went through many cans of paint. I hate painting. |
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As you can see there was hardly a straight piece in the bunch. A lot of holes too. Each bend and hole had to be planned out - this consumed the most of the time - just thinking of where and how to do it. Thus the motivation for this WEB site. |
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Hard to tell, but the charger is actually several inches off the table due to the bends in the rack. Note that Al tape to keep metal flakes out of the charger. |
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A 1" plate of Aluminum serves as a heat sink for the motor controller. There are strips of "U" shape AL on the back for more surface area. Note the cute main breaker mount - which cause me a lot of trouble in thinking how and where to mount. |
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Trial fit of all the relays, shunts and terminal strip on a scrap piece of 1/8" steel. Sometimes you get lucky - it all fit - eventually. |
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Another view. These shots were actually to record the positioning while the plate was in paint. |
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Added a "wing" to mount the plate on the rack. |
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The controller with its connections. During installation I had a great time fighting these cables. Named this beast "The Octopus". |
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Throttle bracket was another case of "where to mount this thing??" Turned out mid-air was the answer! |
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Ended up having to peel open a couple of wiring harnesses to figure out where things went. A lot of the old power cable hit the floor. |
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A standoff look at everything under the hood. |
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Close up of controller side (the black box). |
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Light blue box is DC to DC converter (120 VDC to 12 VDC). Note the many fuses to safe the instruments from the 120VDC pack power! After all this - the motor is waaay down under all this stuff. You have to lean in to see it |
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