Order controller and cooling system

I ordered the Zilla from www.evsource.com because they also offer a packaged cooling system. I was thinking of using the stock overflow tank and the heater core or a regular oil cooler from Kragen, but I would still have to get a pump and their kit was much cleaner and about the same price. The Zilla will take about 4 months to deliver, so it’s good to order it *way* in advance.

Sold more parts on craigslist

Finally sold the AC system and ECU! Buyer thought I was putting a V8 in the car and was puzzled to see what I was really doing.

Rear rack complete

After Christmas I was able to get the rear rack done – finally! I don’t think it was my welding kit after all, I was just over-thinking the process and taking a few shortcuts that backfired on me. For instance, to insure the two pieces of steel were aligned, I would clamp a piece of scrap steel across the gap. It acted like a heat sink and kept the joint from getting hot enough for a good weld. In any event, I learned my lesson, and the next racks will come together much faster.

Ordered gauges

I wanted to get a state of charge rather than a volt meter. I think it would be easier to see what % of charge is left rather than having to know what voltage was 80% State of Charge (SOC) or 50% SOC. None of the suppliers I found offered a state of charge for 156 volt system. Took some time, but I found the www.westach.com site – these are the suppliers of the gauges to Electo Automotive and EVparts – and they were happy to make a custom gauge for me. The Optima helpdesk questions@optimabatteries.com provided the numbers for 50% and 100% for their yellow top batteries, but unfortunately, the numbers aren’t linear, so the gauge would need to be set for the 0%, 50% and 100% voltage. Westach explained that they can only set 0% and 100%. After some thought, I went with the 50% SOC number for 0% (you shouldn’t go below 50% if you want to your batteries to last anyway). So the gauge will show the *useful* state of charge rather than actual. 80% SOC now shows as 40% - a little confusing, but I think I can live with it.
I ordered a 1000 amp gauge and, since the gauges will look different than stock, a matching temp gauge for the controller. I plan to put the 3 gauges in the stock instrument cluster.

Adapter in!

Adapter arrived today. It’s made out of two pieces not including the flywheel hub. Billet aluminum - looks like something off a hotrod.

Bought new welding kit on eBay

Bought a new Victor FirePower (medium duty) $133 w/ shipping from www.weldingsuppliesfromioc.com. New regulators, handle, tip, gauges and goggles. The handle has back fire suppressor, which sounds good to me. I know it’s not professional grade, but that’s okay for what I’m using it for.

More steel for rack

Bought more steel for the rear rack. I’ve been re-reading my welding book and think the tip I have is too small. Took it into a welding supply store and they told me it’s old and an off brand that will be hard to find.