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Old 11-27-2007, 02:27 PM   #450 (permalink)
MetroMPG
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Join Date: Nov 2007
Location: 1000 Islands, Ontario, Canada
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Blackfly - '98 Geo Metro
Team Metro
Last 3: 70.09 mpg (US)

MPGiata - '90 Mazda Miata
Last 3: 51.27 mpg (US)

Winter beater Metro - '00 Chevrolet Metro
90 day: 58.31 mpg (US)
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10-02-2007, 10:41 Pm

On the issue of DIY soldered cable ends... I'm discovering they're not that much cheaper than lugs. I've used 1.5 baby tanks of acetyline & a roll of solder @ $47 total. So far I've made about 22 ends. So each one cost about $2, not including my time (I've got it down to about 5 minutes each, but the average is certainly way higher).

Maybe I'm just paying too much for acetylene?

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Brake circuit contactor relay... Yeah, my mom's e-bike has the same safety feature (controller cuts out if either brake lever is pulled).

I thought about using the brake circuit, but if releasing the throttle fails to remedy the full-on controller situation in the first place (ie. the contactor welds), then attempting to release a second contactor (of the same rating) via the brake light circuit will likely have the same result.

Besides, for people who have always driven stick, jamming down both the brake AND the clutch simultaneously in a panic stop situation is an automatic response (pardon the pun). So the mechanical disconnect on the end of the clutch cable should do the job.

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Update-o-rama:

It's close... it's very, very close...

The 300A main fuse & accelerator contactor are mounted on the component panel and nearly all hooked up.

Pretty much all that's left to do is make one more short cable, secure said cable and several others with straps, and mount the controller precharge resistor (a spotlight scavenged from the forklift).

I should be able to get this stuff done tomorrow.

So I'm going to call and schedule the inspection. Here's hoping he can fit me in before the weekend.
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