EnviroKarma.org - Electric Vehicle (EV) Conversion
'...it's (NOT) hard to be Green' - what Kermit should have said
Turned out that in summer heat, the controller was getting hotter than I preferred. I could still hold my hand on it, but hey is NOT good for controllers and I didn't want to add fans.
After marking the actual interference with the mid-rack, I decided to try NOT cutting a hole in the hood, and just making a 'bump'.
If things got hot, I figured I could always come back and cut a hole and add a scoop. If things stay cool without a scoop, I would change the mid-rack design for future converstions to minimize the height by not having a top rail, and much simplified heatsink mounting. Without a drip shield and no need for complex edges to seal against the mounting of the heatsink/controller would have been 4 hours or more faster....
If you click on the final image to see the bigger picture... check out the windshield graphic! I put one on the rear window as well. It turns out to be not that expensive to add custom vinyl lettering. These were $45 each (front and back). I just couldn't help it! The sign shop guys almost have me convinced to spring for a 'full body wrap' instead of painting...
A good friend looking out for my sense of style found an inexpensive ($10+$18S&H) plastic hood scoop for me to cover the ugly hole I made in the hood. He found it on ebay, but similar items are all over the web for less than $20.
I stuck it over the hole, and added a little 'great stuff' along the back edge to help keep it stuck and direct air smoothly down into my heatsink ductwork. After initial squirts, I laid in some Press-n-seal saran from the inside so I could shape it slightly as it cured and provide a plastic surface to resist soaking up water.
The details of the process is in the Gallery...
cutting inside braces and 'bumping' hood: 1 hr
adding latch support and installing hood: 2 hr
cutting hood for intake: 1 hr
adding plastic scoop... 1 minute. ;)
total : 4 hrs
Web Site Design and Maintenance By
Emerging Technology Services
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.