Electric Starion - Electric Car Conversion - Part 6

After successfully testing the Starion drivability of the electric car conversion so far, it's back to the workshop to get stuff removed to paint the battery racks and sort the best place for the charger and finally add the tacho sender to the gearbox adaptor plate. The fuel port assembly is done now also; I cleaned up the inner rubber mount and gasket-sealed the hole with a rubber bung where the original fuel inlet was, and Nathan cut out the new hole for the power through to a new fascia plate where the 20A connector will be mounted. A shut-off switch is added which is essential when 'filling up'; some folks use micro switches like the ones in arcade machines in their EV fuel ports but we're using a brake switch which will be more durable and it's long thread allows us to fine-adjust the profile of the switch so that it triggers properly when the fuel door is opened/closed. An annoying short had to be traced under the dash (oops, I forgot to ground a 5W resistor), and you'll meet our little helpers at the end of the video. Cuuuute...

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Electric Starion EV - Electric Car Conversion - Part 7
Getting seasonal obligations out of the way, this video should be near the last we're doing as the car approaches completion. There's a brakes and air-con/pwr steering test, Nathan talks about water boilers used to cool engine bays in cold climate countries that could be used for cabin heating in an EV, I talk a bit about IGBTs and Nathan does a tacho send test using an IGBT. Sooner or later there may be motor speed controllers custom designed for EVs that use IGBTs. These things have freewheeling diodes, and from my limited understanding that means they're there to stop reverse current voltage spikes across the inductive load. When the current flow to an inductor is suddenly interrupted, the inductor attempts to maintain the current by reversing polarity and ramping up the voltage to maintain the flyback. Without the diode the voltage can go high enough to damage the IGBT. The diode allows the reverse current to flow through it and dissipate. IGBTs could be cool things to use for 'electric Boost' -just like a turbo Boost. From the video you can also see the BMS installed - these will be sprayed with conformal coating for protection. Most of the scenes in all the videos have been shot on a Nokia N93 which has been very handy. Thanks to Nathan, Linda and Christina for the filming. And sorry about the seasonal sillyness.

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