2/0 Cable and crimping

The last few days we've been working on running our 2/0 cable between the batteries, controller, and motor. The lugs we use are Magnalugs from Quickcable. These are heavy duty lugs that allow the amperage to flow from the batteries to the controller then to the motor. We crimp these with an awesome "made in the USA" crimp too.


Check out this vid to learn about QuickCable connectors

Mr. Butler demonstrating the "hold tight and push tight" crimp method.

No matter how hard you pull... as Mr. Butler says "That joker's on there!!"

Now its time for Jesse to become the cable expert and cut, crimp, and heat shrink all the cable connections.

Always be careful of HIGH VOLTAGE! When batteries are strung in series their voltage INCREASES.

Quintin getting removing the old clear tube sheath from old cable. This will be cleaned and installed in our EV.


Spencer loving it!

Tails and Carpet

Our electric vehicle project was equipped with stock '87-93 LX tail lights. Although the stock lights are nice the lens was both faded and cracked. The lenses provided from Latemodel Restoration are of the older SVO style. We love the black stripes and the retro look!!! We removed the stock lens from the housing by simply prying them off. Next Tyler Haney scraped out the adhesive and Clinton cleaned the housings.

The housing was cleaned...some Mothers' Back to Black was added on top of the housing to provide the rich black look.

Clinton adding the adhesive so the new lens can be glued into place.

As expected the interior carpet from 2 decades of use was extremely pitiful. Again Latemodel helped us out by supplying a new titanium gray carpet. The pics below show how the install went.

This is the interior before cleaning. We also removed the console bracket behind the parking brake since we are doing a console delete.

Clinton helping to layout the new titanium gray carpet

Holes have to be cut for the shifter, parking brake, seat. The carpet is easy to cut but hard not to cut too much.

Spencer and Eli check out a job well done.

Door Moldings and Weather Strip

Our team recently completed the install of new door moldings and weatherstrip provided by Late Model Restoration. The previous weather strip and moldings have become extremely worn, and were in need of being replaced. Late Model Restoration supplied moldings and weatherstrip for both doors, all windows, the trunk, and windshield.

Previous window molding (top) compared to new molding (bottom).

Clinton finishing up on replacing the door moldings.

Brand-new door molding supplied by Late Model Restoration after being installed.

The next step in our vehicle's progress is installing the controller, DC/DC Converter and auxiliary battery before the EV Challenge next week.

Door hinge bushings and striker install

On face value one would think that fox body door hinges would be a fairly simple install, especially since our EV conversion already has the fenders off. But when years of rust and wear have set in, I can tell you first hand the install is not easy.

These are the door repair components received from Late Model Restoration Supply. They include: 1) Pin and Bushing Kit 2) Door Roller and 3) Door Striker.

After breaking two of the stock bolts when taking off the doors we found a lot of rust had set in. The factory does not do a good job priming/painting this area and many cars have a similar problem

.

After clean the door hinge area we painted the surface using POR15. This protect is a rock solid protectant. We shouldn't have anymore trouble w/ rust at the hinges.

After the area was painted, Hunter and Quintin Started the install of the door hinge bushings. The stock hinge pin must be ground door and forced out with a punch. The new bronze bushings can be easily damaged. Quintin taps them carefully using a metal rod in the pic.

The roller must also be installed using a punch. Since the door skin is curved the install is NOT easy!

Hunter, Quintin, and Clinton completing the door to chassis install.

Clinton installing the door striker provided by Late Model Restoration. After the striker is installed it must be adjusted so the door closes correctly.

Battery Rack Install

Our team has recently started the process of cutting a hole in the car where the spare tire once was, to make room for two battery racks. We first tested the measuring and cuts on an older Mustang before cutting into our project Mustang. The tests were very successful, so we moved onto our project car. Pilot holes were first drilled into the corners of the planned hole, to make the cutting easier. We then used a grinder to make the first cuts in the thin sheet metal. After the first cuts were made, a plasma cutter was used to make the final cuts and clean up any excess metal. After the hole was cut, the battery racks fit snugly into the hole. The racks will later be secured to the sub-frame of the car to prevent them from moving.

Mr. Butler, Hunter Foulks, Spencer Griffin, and Jesse Gilbert debate on how to install the front battery rack.

Mr. Butler, Hunter Foulks, Eli Strickland, and Jesse Gilbert test the fit of the rear battery racks in our older Mustang.

The test cut made on our team's older Mustang.

Mr. Butler uses a plasma cutter to make final cuts and trim off excess metal.

Spencer Griffin trimming off excess metal and smoothing any sharp edges.

First battery rack installed into the project car.

Spencer Griffin and Mr. Butler measure the hole to install the next battery rack.

New Interior from Late Model Restoration Supply

Late Model Restoration Supply is one of the leading supplies of parts and accessories for 79-current mustangs and many other vehicles. They have agreed to sponsor our endeavor to create an electric foxbody mustang.




Our team recently received most of the interior parts needed to give our project a cleaned refreshed stock look. All cars in the SMARTT Challenge need to look as stock as possible as part of the Final Event. We received new moldings and weatherstrip for all of the doors and windows on the car, as well as new carpet for the inside of the car. As part of the project, the team has decided to insert what is called a rear-seat delete in order to remove the rear seat to save weight. The rear seat delete allows the seats to be removed, while covering the spot where the seats once were. This creates a clean install, making the interior of the car look like it is stock. We have also received new side view mirrors for both sides of the car, as well as new brake-light lenses. We have also received new door-strikers and other small components for all of the doors.

The boxes containing the new interior parts from Late Model Restoration Supply.

New door moldings for our car from Late Model Restoration.

Spencer Griffin fits a new brake lense over the old. Lenses supplied by Late Model Restoration.

Rear-seat delete supplied by Late Model Restoration.

Instrument pod supplied by Late Model Restoration.

New carpet for the interior of our car, supplied by Late Model Restoration.

Our team has recently started the process of cutting out the space where the spare tire once was to make room for the new battery racks we received from GP Fabrications of Reidsville. After the batteries are installed the car will be well on its way to being completed.

Auxilary Battery and Cable

Our team has recently received a 12-volt battery as well as a 96v cable that will be used to connect the batteries to the controller and motor from Interstate Battery Company. The 12-volt battery will be used as an auxiliary battery to power the car's headlights, brake lights, turning signals, etc., without pulling energy from the main batteries. In order to keep the auxiliary battery from being depleted, we will run a DC/DC Converter from the main batteries to the smaller auxiliary battery. The DC/DC converter serves the same purpose as an alternator in an internal combustion engine vehicle, but without a belt that takes away energy from the motor. The auxiliary battery is also capable of being mounted at various angles because it is a dry-cell battery instead of a wet-cell battery. Interstate Battery has also donated a 50-foot piece of cable that is used for welding to our team to use as connecting cables for the batteries, controller, and motor. This cable is much more flexible than most cables of the same capacity, which is perfect for use in our car.

12-Volt auxiliary battery donated by Interstate Battery Company

50-Foot cable donated by Interstate Battery Company

Cable and Battery together.

The next step in our project is mounting the main batteries when the battery rack arrives, and getting them in place. We still have to complete the interior of the car, finish upgrading the breaks, and place the batteries before the competition in a few weeks. We hope to continue making progress, and complete the car on time.