More progress

Some of the cables are left disconnected in these pics; these are the jumpers between groups.  These are the last to be installed, this minimizes the number of instances while working that lethal voltages are potentially present.  First jumpers are installed between every other 12v segment to create 24v groups, below the lethal voltage. These are then jumpered to create 48v packs, this is when it starts to get dangerous, and any action around the batteries is thought out carefully beyond this point as to eliminate the risk of a dropped wrench, accidental shock, or any other hazard associated with high voltages with a great deal of current potential.  All tools used around or in the engine bay are covered entirely with heavy duty heatshrink tubing. 1″ Works well for smaller wrenches. Electrical tape could also be used but I’d rather not get my tools covered in a sticky residue if possible, the heatshrink (being of the non-sealant variety) cuts off with relative ease at any time.

240zev SOLD! Pictures, progress, new specs

The configuration has changed in anticipation of a sale to a new owner in Boston.  Power is now supplied by a bank of 30 u-1 gel batteries, 33ah each.  Peak power is sacrificed for increased total capacity and better life under deep daily cycling.  They are arranged as 10 groups of 3, 6 groups (18 batteries) in the front and 4 groups (12 batteries) in the back under the floor of the hatch.  Total pack weight has decreased from 780lbs to 720lbs while total capacity increased to 12,000 watt-hours.  The use of lighter gauge steel and nylon straps to secure the batteries resulted in 40 lbs of reduction of battery hardware, plus at least 20 lbs saved by using 1awg cable instead of 4/0 awg.  Safety is being improved by moving all traction wiring outside of the cabin as well as the installation of a second contactor for full pack isolation while charging.  The 1000A controller will be turned down to ~700A to better suit the current limitation of the gels and to better suit the normal driving conditions expected.  Additional pictures will follow as the vehicle is readied for transport to its new owner.