Problems Solved!

We solved the potentiometer issues, and Stan of Middle Peninsula Golf Carts wired up a charging port and let us borrow a charger.  It turns out that we had the forward/reverse control wires coming from the potentiometer wired to the controller.  We simply plugged in the other white/black wires running from the potentiometer and our problem was solved!  Thank you very much to Middle Peninsula Golf Carts for advising us, wiring up the motor controller, and allowing us to borrow a charger.

We later drove to Mr. Joyce's house and Marshall's house.  After the trips, the Corolla was almost completely dead, so it received its first charge!

The First Drive Under Electric Power

Today, Aidan and I had a very exciting day. We left school early to pick up a trailer so we could tow the car. It turns out that the trailer was too much for the poor little Discovery, so we rented one from uhaul. We then towed the electric car from w-burg to our friends at Middle Peninsula Golf Carts. There, they wired up the control and told us how we could program it at home. Well, after some trial and error, we wired everything up properly and were able to connect the controller to the computer through the antiquated "Comm port." Well, we are immensely pleased. We have to sort out the controller's current on/off nature and perhaps, later, the transmission issues. The videos speak for themselves!

Wiring up the car

We are at middle penninsula golf carts wiring up the car.  It's a bit different, so they are using the time tested trial and error method.  We had to rent a trailer that was self braking, so we could tow it with the discovery.  Thank you to Mike, though, for offering his trailer.

Buying more cable

Aidan guestimated wrong, so we bought 13 more feet of cable!

Wiring!!!!!

This weekend, I used the aforementioned cable lugs from NAPA and wired the battery pack together. We still need to wire the pack to the solenoid, the solenoid to the controller, and the controller to the motor. I also mounted the potentiometer box so that the cable throttle can now be translated into electric motor controller language. We are almost there. The only thing left to buy is the charger. After that, off to see if we can get a paint job donated as the paint looks really sad.

Cable Lugs and Solenoid

Today we picked up 25 copper cable lugs from NAPA that will connect the the cable to the batteries!  We needed 23 but figured that 2 more wouldn't hurt.  We also bought a solenoid from Middle Peninsula Golf Carts.  We'll probably wire it up sometime next week!

Mounting the Batteries... Part Deux

We finished mounting the batteries!  Two days and 20 pounds of angle iron later, we have a nice setup that evenly distributes the weight.  We are so clever!  The mounts look rather simple, but they took so much effort.  We had to construct and support the trays.  We then had to "massage" (cut bits off of) the grill and headlight so that the batteries would fit.  We also moved the horn a few inches.  Now that it is shoved up against the grill, it makes a very endearing little squeak.  Anyway, now all of the heavy lifting is done.  We just have to buy some wire, buy a charger, and visit Middle Peninsula Golf Carts so they can help us wire it up.

Mounting the Batteries... Part 1

Today we mounted the back five batteries.  We used angle iron to squeeze the batteries together and then secured them from side to side with a long bungee cord.  As you can see from the video, it looks pretty professional :).  More to come tomorrow when we finish mounting the batteries in the front bumper.  We could fit all eight in the trunk, but we are distributing them for suspension happiness/weight distribution purposes.

Batteries!

We picked up and paid for the batteries and controller.  We then placed the batteries in the car to sort of mock the weight distribution when they are mounted.  The poor Corolla's suspension will indeed support the batteries.

Batteries

So, today after a period of relative inactivity, we paid for and brought home the batteries and the motor controller. By far the most expensive part of the build, the battery pack consists of 8 unpleasant to move 6 volt lead acid deep cycle batteries. Three will be mounted under the hood on the front chassis cross-member and the other 5 will be mounted in the trunk. The videos chronicling this exciting day will soon be posted.