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


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

    The Controller installation gets its own page because it is pretty complex in my case where I am constructing a ducted cooling system and active hoop scoop. The first picture shows the charger and controller just balanced leaning against the mid-rack aproximately where they will end up. Look like its all going to fit together...

    I got a big hunk of heatsink after searching around on the internet... Found a great guy at www.heatsinkusa.com who is a machinist at a big company and bought a couple dies for himself and makes small runs on demand. (added after operational testing) The added surface area from all the fins do a GREAT job cooling, and the controller is barely warm to the touch.

    I used 1 x 1 AL angles to standoff the heatsink from the backing plate. I am thinking this will allow freer airflow, and allow leaves or birds and bugs to wash thru. ;) The top edges I tried to design so that I can add mouldings and seal up against the hood scoop, and the bottom has a little angle where I will attach a plastic skirt to try to make sure water drains past motor terminals and vents. The battery charger backing plate I also made out of AL... a recycled street sign from the salvage yard

    Time to design on paper: 1 hr
    cut, drill, tap, trim, mount heat sink, controller and charger :9 hr
    add plastic drip guard : 3 hr
    total : 13 hrs


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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.