Ben's "Cougar" ReVolt Controller

[bennelson]

Well, I started my waterproofing solution for the controller.

I stopped at the thrift store and bought the largest toaster over they had. (on sale, 25% off!) I figured it will get some use on various other future projects.

I baked the ENTIRE controller for a couple hours total. The logic board has all those little gate resistor wires connecting it to the power board. I wasn't about to desolder all those!

After I pulled the controller from the oven, I sprayed down the logic board with a clear, acrylic-based topcoat. It's gloss, so it makes the control board look nice and shiny!

Right now, the board is drying. Then I plan to put the original cover back on, and use silicon sealant to weatherproof on the lid and the clear plastic ends.

[jyanof]

Just to add a tidbit, I haven't had a problem yet with moisture, but that probably isn't surprising given that humidity in PHX is often around 15% or less. I've driven in the rain before too, but that would still only be a few consecutive days of slightly more humid conditions.

I'm glad I read through this thread though, since coating the board sounds like a good thing to do anyway and I plan on building another controller at some point.

[bennelson]

In taking out the controller, I also did some testing with the voltmeter from controller and motor to the frame of the car.

There is some spare voltage floating around. I think that all the rain soaking we have been having around here could also have been conducting parts of things to other parts of things in a bad way.

I might have to just look over every single battery cable, connection and post to see where that's coming from.

[apowers]

I have FLA batteries and get an acid mist build up that does carry voltage to the frame but I don't think it carries enough current to harm anything. I hope.
Alvin

[Hondo]

I get the same thing with my FLAs. Right now if I measure from my 108 volt lead to ground I get 56.8 volts. I can feel it if I hold the lead and touch ground with my forearm. I can't really feel it if I use both hands (caloused hands). I tried to see if it was enough current to light a 12 volt bulb. It wasn't. I have found that as you measure down the battery chain, you will find the guilty culprit. About the middle of my pack I have a battery that measures 6.4 volts (6 volt battery) from positive to negative terminals. But from positive terminal to ground is a positive 5.8 volts and from negative terminal to ground is a negative .8 volts. This has happened to me before, and I just pulled that battery and cleaned it really good with baking soda/water solution, and the problem went away- for a while.

Hondo

[bennelson]

I weatherproofed the controller.

Baked that sucker in the toaster overn, then caulked the whole thing with clear silicone.

Hope that helps!