15 October 08 Update

We've been busy with the truck but just now getting around to updating the blog.  Found out the emergency brake problem was only needing an adjustment so that's fixed now. 

Got the battery racks finished under the bed except for painting and lining the boxes.  My US2200 batteries measure 7x10.25x9.5T plus 1.25T extra for the battery posts. I'm going to use political signs to line the boxes, a good use for them!  I managed to get 22 batteries under the bed.  14 batteries straddle the drive shaft  and 8 are behind the rear axle.  Two on each side of the drive shaft slide under the cab a few inches but that won't be a problem.  I'll undercoat the cab to protect it from the acid fumes.  I welded an angle iron across the frame under the truck to attach the two racks paralleling the drive shaft.   This gives me a total of 132V under the cab.  I'm putting two more under the hood to get my 144V. 

Be precise in your measurement if you copy my drive shaft racks.  The drive shaft is a bit off center and the passenger side is very tight and close to touching the drive shaft.  If that becomes a problem, a custom shaft can be made from yours making it an inch or so thinner.  Note: In order to carry the weight of 22 batteries under the bed, I replaced the factory 2300lb rated drum brake rear axle with a disc brake unit from a blazer.  This unit is rated at 2900 lbs so I'm not in danger of overloading the axle as the pack will weigh about 1500lbs with the steel and cables + 1100Lbs of the curb weight.

Also have the motor/transmission assembly installed and have tested the motor with a battery charger.

Removed the heater core and purchased an electric one from EV-America.  These are good people to use.  They'll help with your questions and their pricing is very good.  You can find things a bit cheaper if you try on most things but it's worth a little more to get all their help.

This is a slow process for me, slower than I want but I have other things that come first...

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one comment:

Good for you putting the batts under the bed. Mine are on top and it’s a pain to loose the use of the box. Make sure you can get at the terminals for those 2 under the cab. They need tightening often at first and I check mine every time I fill the water. A loose one can turn the post into a pool of lead.
Pat () - 31 10 08 - 23:55

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