Go Back   EcoModder Forum > EcoModding > EcoModding Central
Register Now
 Register Now
 

Reply  Post New Thread
 
Submit Tools LinkBack Thread Tools
Old 04-25-2020, 10:01 PM   #111 (permalink)
Administrator
 
Daox's Avatar
 
Join Date: Dec 2007
Location: Germantown, WI
Posts: 11,203

CM400E - '81 Honda CM400E
90 day: 51.49 mpg (US)

Daox's Grey Prius - '04 Toyota Prius
Team Toyota
90 day: 49.53 mpg (US)

Daox's Insight - '00 Honda Insight
90 day: 64.33 mpg (US)

Swarthy - '14 Mitsubishi Mirage DE
Mitsubishi
90 day: 56.69 mpg (US)

Daox's Volt - '13 Chevrolet Volt
Thanks: 2,501
Thanked 2,585 Times in 1,553 Posts
I went with the 10 gauge. 40A should be fine.

I worked on the project again today. This time I worked on the pack. Doing it earlier would have been easy, but I didn't! So, I had to drill holes and make bus bars for the pack. This was interesting, but thankfully its aluminum and its soft and easy to drill. I held a small wood block under the bus bars while center punching and drilling which made it go alright. I also later marked the positives and negatives with a sharpie for easier identification.






Attached Thumbnails
Click image for larger version

Name:	altdel01.jpg
Views:	244
Size:	57.8 KB
ID:	27947   Click image for larger version

Name:	altdel02.jpg
Views:	260
Size:	48.3 KB
ID:	27948   Click image for larger version

Name:	altdel03.jpg
Views:	256
Size:	59.9 KB
ID:	27949  
__________________
Current project: A better alternator delete
  Reply With Quote
The Following User Says Thank You to Daox For This Useful Post:
Ecky (04-26-2020)
Alt Today
Popular topics

Other popular topics in this forum...

   
Old 04-26-2020, 01:22 PM   #112 (permalink)
Administrator
 
Daox's Avatar
 
Join Date: Dec 2007
Location: Germantown, WI
Posts: 11,203

CM400E - '81 Honda CM400E
90 day: 51.49 mpg (US)

Daox's Grey Prius - '04 Toyota Prius
Team Toyota
90 day: 49.53 mpg (US)

Daox's Insight - '00 Honda Insight
90 day: 64.33 mpg (US)

Swarthy - '14 Mitsubishi Mirage DE
Mitsubishi
90 day: 56.69 mpg (US)

Daox's Volt - '13 Chevrolet Volt
Thanks: 2,501
Thanked 2,585 Times in 1,553 Posts
More progress!

I busted open all the plastic shells on the AC power supplies. This took a while and was a pain, but it definitely allows for more flexibility, cooler operation, and lighter weight.





Next up, I desoldered the 2 pin AC plug from each board, and daisy chained them with some new wire. The last one has a new wire to reconnect the AC plug, but it'll be mounted in the new enclosure.






I connected the AC supplies to the DC-DC converters (for charging).





Now, time for some assembly! The side panels went on, and the AC power supplies were put into their mounting slots. Hey, its finally looking like something, yay.





Then, I connected the DC-DC outputs to the battery pack.

This pretty much takes care of the charging side of things besides mounting the AC plug. I haven't figured this out quite yet.



Attached Thumbnails
Click image for larger version

Name:	altdel01.jpg
Views:	248
Size:	75.4 KB
ID:	27952   Click image for larger version

Name:	altdel02.jpg
Views:	237
Size:	66.5 KB
ID:	27953   Click image for larger version

Name:	altdel03.jpg
Views:	255
Size:	84.6 KB
ID:	27954   Click image for larger version

Name:	altdel04.jpg
Views:	258
Size:	69.8 KB
ID:	27955   Click image for larger version

Name:	altdel05.jpg
Views:	262
Size:	73.8 KB
ID:	27956  

Click image for larger version

Name:	altdel06.jpg
Views:	266
Size:	75.7 KB
ID:	27957  
__________________
Current project: A better alternator delete
  Reply With Quote
The Following 2 Users Say Thank You to Daox For This Useful Post:
Ecky (04-26-2020), hayden55 (04-27-2020)
Old 04-26-2020, 07:13 PM   #113 (permalink)
Master EcoModder
 
redneck's Avatar
 
Join Date: Jun 2009
Location: SC Lowcountry
Posts: 1,795

Geo XL1 - '94 Geo Metro
Team Metro
Boat tails and more mods
90 day: 72.22 mpg (US)

Big, Bad & Flat - '01 Dodge Ram 3500 SLT
Team Cummins
90 day: 21.13 mpg (US)
Thanks: 226
Thanked 1,353 Times in 711 Posts
.

Just wanted to drop in and say you do nice work.

Neat, clean and well thought out...

Looking forward to the finished product.





>
  Reply With Quote
The Following 2 Users Say Thank You to redneck For This Useful Post:
Daox (04-27-2020), Ecky (04-27-2020)
Old 04-27-2020, 11:09 AM   #114 (permalink)
Administrator
 
Daox's Avatar
 
Join Date: Dec 2007
Location: Germantown, WI
Posts: 11,203

CM400E - '81 Honda CM400E
90 day: 51.49 mpg (US)

Daox's Grey Prius - '04 Toyota Prius
Team Toyota
90 day: 49.53 mpg (US)

Daox's Insight - '00 Honda Insight
90 day: 64.33 mpg (US)

Swarthy - '14 Mitsubishi Mirage DE
Mitsubishi
90 day: 56.69 mpg (US)

Daox's Volt - '13 Chevrolet Volt
Thanks: 2,501
Thanked 2,585 Times in 1,553 Posts
Thanks redneck! Its nice to hear good feedback. Its taken a lot of time to put it all together. I hope it actually works well haha.
__________________
Current project: A better alternator delete
  Reply With Quote
Old 04-27-2020, 02:48 PM   #115 (permalink)
Master EcoModder
 
Join Date: Dec 2010
Location: USA
Posts: 1,168

Sport Utility Prius - '10 Toyota Prius II
90 day: 52.98 mpg (US)

300k Sequoia 4WD - '01 Toyota Sequoia Limited 4wd
90 day: 20.19 mpg (US)
Thanks: 352
Thanked 265 Times in 212 Posts
Hey Daox,

Are you 3d printing these yourself?
__________________
"I feel like the bad decisions come into play when you trade too much of your time for money paying for things you can't really afford."
  Reply With Quote
Old 04-27-2020, 04:08 PM   #116 (permalink)
Administrator
 
Daox's Avatar
 
Join Date: Dec 2007
Location: Germantown, WI
Posts: 11,203

CM400E - '81 Honda CM400E
90 day: 51.49 mpg (US)

Daox's Grey Prius - '04 Toyota Prius
Team Toyota
90 day: 49.53 mpg (US)

Daox's Insight - '00 Honda Insight
90 day: 64.33 mpg (US)

Swarthy - '14 Mitsubishi Mirage DE
Mitsubishi
90 day: 56.69 mpg (US)

Daox's Volt - '13 Chevrolet Volt
Thanks: 2,501
Thanked 2,585 Times in 1,553 Posts
Yes I am.
__________________
Current project: A better alternator delete
  Reply With Quote
Old 04-28-2020, 08:00 PM   #117 (permalink)
Administrator
 
Daox's Avatar
 
Join Date: Dec 2007
Location: Germantown, WI
Posts: 11,203

CM400E - '81 Honda CM400E
90 day: 51.49 mpg (US)

Daox's Grey Prius - '04 Toyota Prius
Team Toyota
90 day: 49.53 mpg (US)

Daox's Insight - '00 Honda Insight
90 day: 64.33 mpg (US)

Swarthy - '14 Mitsubishi Mirage DE
Mitsubishi
90 day: 56.69 mpg (US)

Daox's Volt - '13 Chevrolet Volt
Thanks: 2,501
Thanked 2,585 Times in 1,553 Posts
Today I added the AC plug, XT60 plug, and the large relay for the low voltage cutoff. I am really liking how it is looking.

I'm still debating adding some other features. Things I'm thinking about adding are an on/off switch for the dc/dc converter. There is a switch on it already, so I'd just have to wire in a new one and connect the leads. I'm not sure how essential that would be though as you could fairly easily just unplug it too. The other thing I'd like to have is some form of indicator that tells me when the batteries are charged... This is way more complicated as I've essentially created a constant current / constant voltage charger. A voltage indicator wouldn't really suffice as it'll only tell once its reached the constant voltage stage of charging. Ideas are welcome, but I'm thinking that I'll probably just omit these features for now.





You can see the large relay behind the AC plug in this image.

Attached Thumbnails
Click image for larger version

Name:	altdel01.jpg
Views:	300
Size:	30.8 KB
ID:	27966   Click image for larger version

Name:	altdel02.jpg
Views:	277
Size:	58.0 KB
ID:	27967  
__________________
Current project: A better alternator delete
  Reply With Quote
Old 04-29-2020, 10:38 AM   #118 (permalink)
Administrator
 
Daox's Avatar
 
Join Date: Dec 2007
Location: Germantown, WI
Posts: 11,203

CM400E - '81 Honda CM400E
90 day: 51.49 mpg (US)

Daox's Grey Prius - '04 Toyota Prius
Team Toyota
90 day: 49.53 mpg (US)

Daox's Insight - '00 Honda Insight
90 day: 64.33 mpg (US)

Swarthy - '14 Mitsubishi Mirage DE
Mitsubishi
90 day: 56.69 mpg (US)

Daox's Volt - '13 Chevrolet Volt
Thanks: 2,501
Thanked 2,585 Times in 1,553 Posts
I am now thinking I would like to put an on/off switch on this dealy. I hooked up the low voltage disconnect to a power supply today to play with it and found out that the LED display stays lit all the time. I was hoping it was timed to turn off, or reduce brightness or something. But, it stays on all the time. The current draw isn't massive, but its definitely measurable at .02A. Considering the pack is 20.8Ah, it would drain itself in a bit over a month. It only stops drawing power once the voltage is under 3V. If I ever set it in storage for a while it wouldn't be good as it would totally murder the battery pack.

Attached Thumbnails
Click image for larger version

Name:	lvdc.jpg
Views:	260
Size:	78.0 KB
ID:	27975  
__________________
Current project: A better alternator delete
  Reply With Quote
Old 04-30-2020, 11:43 AM   #119 (permalink)
Administrator
 
Daox's Avatar
 
Join Date: Dec 2007
Location: Germantown, WI
Posts: 11,203

CM400E - '81 Honda CM400E
90 day: 51.49 mpg (US)

Daox's Grey Prius - '04 Toyota Prius
Team Toyota
90 day: 49.53 mpg (US)

Daox's Insight - '00 Honda Insight
90 day: 64.33 mpg (US)

Swarthy - '14 Mitsubishi Mirage DE
Mitsubishi
90 day: 56.69 mpg (US)

Daox's Volt - '13 Chevrolet Volt
Thanks: 2,501
Thanked 2,585 Times in 1,553 Posts
I dug in my parts bin and came up with a nice power switch for the alt delete. Its a panel mount switch with a nice nut on the back to screw it in.





However, when I threw it in the 3d model, it just looked dumb. It stuck up way too far, blocked the view to the LED display and the buttons.





So, I decided to mount it flush with the top of the case. I think it will look and function much better.





This of course meant that I couldn't just use the switch's included mounting nut sadly. So, I had to design a mounting bracket to hold the switch to the top plate.

I just threw this together to show an example of what goes into designing this thing.

Attached Thumbnails
Click image for larger version

Name:	altdel01.jpg
Views:	255
Size:	30.3 KB
ID:	27982   Click image for larger version

Name:	altdel02.jpg
Views:	224
Size:	30.7 KB
ID:	27983   Click image for larger version

Name:	altdel03.jpg
Views:	236
Size:	40.5 KB
ID:	27984   Click image for larger version

Name:	switch.jpg
Views:	260
Size:	42.8 KB
ID:	27986  
__________________
Current project: A better alternator delete
  Reply With Quote
The Following User Says Thank You to Daox For This Useful Post:
Ecky (04-30-2020)
Old 05-01-2020, 11:16 AM   #120 (permalink)
Batman Junior
 
MetroMPG's Avatar
 
Join Date: Nov 2007
Location: 1000 Islands, Ontario, Canada
Posts: 22,513

Blackfly - '98 Geo Metro
Team Metro
Last 3: 70.09 mpg (US)

MPGiata - '90 Mazda Miata
90 day: 52.71 mpg (US)

Even Fancier Metro - '14 Mitsubishi Mirage top spec
90 day: 70.75 mpg (US)

Appliance car - '14 Mitsubishi Mirage ES (base)
90 day: 60.16 mpg (US)
Thanks: 4,058
Thanked 6,957 Times in 3,602 Posts
Question: do the converters have LED's to indicate they're working? Would make monitoring / troubleshooting easier if one fails.

__________________
Project MPGiata! Mods for getting 50+ MPG from a 1990 Miata
Honda mods: Ecomodding my $800 Honda Fit 5-speed beater
Mitsu mods: 70 MPG in my ecomodded, dirt cheap, 3-cylinder Mirage.
Ecodriving test: Manual vs. automatic transmission MPG showdown



EcoModder
has launched a forum for the efficient new Mitsubishi Mirage
www.MetroMPG.com - fuel efficiency info for Geo Metro owners
www.ForkenSwift.com - electric car conversion on a beer budget
  Reply With Quote
Reply  Post New Thread


Thread Tools




Powered by vBulletin® Version 3.8.11
Copyright ©2000 - 2024, vBulletin Solutions Inc.
Content Relevant URLs by vBSEO 3.5.2
All content copyright EcoModder.com