EnviroKarma.org - Electric Vehicle (EV) Conversion '...it's (NOT) hard to be Green' - what Kermit should have said


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Component Install for the Suzuki Swift (Geo Metro/Pontiac Firefly)...

    I started with the position of the accel cable and potbox, then the main circuit breaker, and developed the layout from there based on what needed to be next to what using my available shelf space on the mid battery rack. I started on carboard, and then did a more exact layout on posterboard that I figured I could use as a template and drill through to locate mounting holes and such. I ended up just referencing my initial layout, and drilling and adding components on the bottom panel.

    After layout of the components, I cut, drilled and welded on the 'walls'. You have to think about the order you do things so that you can get the welding tip in, and pre-drill all the wall penetrations as it hets a lot harder after some components are in place. This top view shows all the components in place except the heater relay, which I added last after hooking up all the fuse wires. The bottom wires are very hard to reach later!

    Time to layout on paper: 2.5 hr
    fabricate box/lid : 6.25 hr
    circuit breaker and pot box linkages : 1 hr
    install electronics and wiring : 18.75 hr
    install mid-rack with box and build remaining 2/0 cables : 3.25 hr
    total : 31.75 hrs

    ...and the final component layout with all cabling and heater relay in place.


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Disclaimer of Liability and Assumption of Risk: Working with high voltages in electric vehicles can be dangerous. Working with welding equipment or plasma torch or sawzall and other power tools necessary to fabricate battery racks or create holes necessary to lay the battery racks within an electric vehicle can be dangerous. The purchaser/builder solely assumes all risk. Further, the viewer of this site, and builder of the vehicle, agree to hold harmless Daniel T. Baker and any associates from all loss, liability, or damage resulting from any failures or defects in any project completed with these instructions. It is suggested that the builder follow common-sense safety procedures, such as the utilization of gloves where working with high voltages, and ear protection and goggles when working with power tools.