Open ReVolt assembly FAQs

[MPaulHolmes]

This is where the Frequently asked questions will go for assembling the motor controller. Clyde has some helpful suggestions. Also, anyone that wants to offer their advice, feel free to add it here too.

[Greg Fordyce]

Hi Paul, great idea to start this thread. I will be first to post my tip.

I pondered for a while on the best way to fix on the Lexan end covers to the Cougar controller kit. Finally came up with the solution of bending the ends of the Lexan so I could screw it to the sides of the cover. See attached pictures. I also used some instant gasket to seal the enclosure from moisture. On the end that has the B+ and B- bars I only used 3 screws, as the fourth one was going to be very close to the capacitors. To bend the Lexan was very easy for me, I let someone else do that! The local high school did that little job with their plastic bender.

Greg

[MPaulHolmes]

Holy mackerel that turned out nice! I didn't know you could bend lexan! What are those white things that keep the cables fastened to the green board? That looks like another very nice improvement.

[Greg Fordyce]

The white things are self adhesive cable holders/clips. I got mine from one of my automotive parts suppliers, but you might find something similar at radio shack. Or you could use instant gasket to glue the wires in a few spots to keep them from moving around, not as pretty, but cheaper.

The plastic bender is basically just a long wire/filament that heats up, and a arm to bend the plastic over. It heats the plastic until it is soft and then you bend it. Might get the same results with a heat gun, a vice and a piece of wood to bend the hot plastic. Practice on some scraps first to get the technique.

Greg