In this step I'll be installing all the main cables into the Tredia. These are the chunky 70mm2 welding cables which have been cut and crimped for me by Simon Reece in Tauranga (Thanks Simon!!).
I took measurements of the required lengths and send the cable away to be cut and crimped. This was something I didn't have the skils or equipment for so it was worth having a pro do it for me. The cables arrived soon after and I got busy installing them that afternoon.
There are two long lengths running from the front of the car into the boot (trunk) and a myriad of smaller lengths running within small sections. I plan on installing the long lengths first to get the hard part out of the way, then install the shorter lengths.
I've already taped up some tools ready to work on the batteries, and I'm going to borrow some 10KV safety gloves for any difficult connections where my hands could touch - and + of the main pack. I also received some good advice to wear eye protection when connecting the last few batteries to reduce the eye danger if one of the batteries were to explode sending acid everywhere (it happened to him). So consider it done, I'll wear safety specs too. I'm normally Captain Safety but I'll make an extra effort at this crucial stage! OSH would be happy. :)
Once the cables are all in, I still have a lot of work to do. I have yet to build my charging system with 12 individual chargers. I have all the chargers now which is good. I just need the spare time to build the charger! After I've taken care of that I then need to get the rear panels properly painted (I have primer on them at the moment) and then transport the car to Auckland to get it's final certification from an EV inspector. That will be a long slow drive, towing the Tredia on a trailer with the Nissan pulling the trailer. It's normally a 4.5 hour drive on a good day. With a car on the back it'll probably take most of the day. If the Nissan survives it of course...
I got busy slithering about under the car and installing the second main cable from the rear battery pack to the front section. It went as well as can be expected. I think for the next conversion (one day) I'll get a proper set of drive-on ramps that raise the car higher than the axle stands I was using. That way I'll be able to fit myself and the drill without as much swearing. :)
After 5 hours of slithering about and finding new ways to fit a very inflexible "flexible welding cable" into the car Rob and I started connecting things ready for the first test drive.
We methodically went through each connection step by step making sure everything was run correctly before flicking the final switch.
It all looked good. We'd followed all the advice given to us correctly so we gave the circuit the all-clear. First we checked we had pack voltage at the circuit breaker... check. I flicked the circuit breaker to "on". Good, we were now getting the 153V of pack voltage at the contactor. I did another double-check that all cables were correctly positioned and with my breath held, I turned the key.
Click.
The connection had been made. My voltmeter showed nothing however... I knew what the fault was; the negative lead for my voltmeter isn't connected. Whew, I can do that tomorrow.
Everything else seemed to check out ok, there were no strange noises or smells. The controller was doing nothing odd.
So I pressed my foot onto the accelerator. Nothing. I pressed down a little more. Still nothing. At this stage the pedal was down about 25%. I was a bit worried but I decided to push a little more... Instantly a high pitched, violin-like sound came from the direction of the controller! I pressed further still and the motor started spinning! I pressed just a little more and WOW does that motor spin easily!
I put it in gear and went through the same process to find it did exactly what it should! No problems at all! I tried all the gears, watching the ammeter draw small sips of power getting the wheels to spin in mid air. I was just brimming over! The feeling of 8 months of work evolving into a successful test spin must been similar to Neil Armstrong walking on the moon!
I checked out the heater too. At first nothing happened. I noticed a 3 amp drain on the battery pack but no heat. I left it running for a minute while I checked things in the engine bay and when I came back it the air was warm from the vents! It works!!! The heat that comes out of it isn't blisteringly hot, but warm enough for driving through winter mornings to be enjoyable!
So a successful Friday evening ending in a test spin of the Tredia for the first time! I'm the happiest EV owner on the planet at this moment in time! I have the EV grin from ear to ear as I type this!
Obviously I couldn't stop there with a simple test spin. A late night test-drive was in order! You'll have to wait for the next video for it though! ;) Don't worry, it'll be up here before you know it! Keep checking the site over the weekend!
