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Electric Starion EV - Electric Car Conversion - Part 4

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Most of the hard part of cabling through the sub-frame has now been done. The car's been pretty well stripped to the bone but all this work should be worth it. While a lot of EV builders get their cabling to run under the car, protecting it in the sub-frame is my preferred option and this has been checked by the road-legal engineer and so far so good. Metal saddles are used to clamp the conduit flex where exposed, so nothing is loose. The main issue has been space in the engine bay, making sure the batteries sit comfortably under the hood and trying to fit the ancillary stuff. With the laser-cut mounting plate for the AC air-con and pwr steer driver motor etc, orientation had to be decided upon, and the battery placement largely dictated this, so its placement may appear odd at first, but will be very secure when completed. Battery balancing was also performed prior to installation and now we're on the road to re-assembling everything, dash, final wiring etc. I bought some Electrolube DCA200H conformal silicon spray for the BMS PCBs but we'll install and test everything first. Some BMS modules such as the TS-90 have all components protected in a resin block and maybe BEV who build the modules in Australia will integrate moisture protection in a future version. Nathan has done an excellent job welding up the supports for the ancillary drive components and the pulley part I supplied (which I happened upon by chance in my big box of junk in the shed) should do the job well for control. Also, the trunk/hatch area is painted and ready for battery installation. The next video will show the batteries installed with their BMS and the car will be (fingers crossed) basically drivable (with cooling system installed later if time runs out (but we've both got jobs to bring in da regular bux so time has been tight)). Despite some other issues with the car, it should be mostly ready for our annual EV show in Sydney (while down the road the bigger money Motor Show shows off the rip-off complicated hybrids and guzzlers - and we wonder if anything will really change and if governments will really listen (it starts by replacing greed with need but convincing them is a difficult thing)). Check out www.electriccarsforeveryone.com for updates, and I'd like to thank you all for your great support and comments (even the naughty ones are appreciated ;-P ). Oh, sorry re miscount on episode version (working on cars and video's and doing jobs means we're both need a hell of a lot of sleep!)

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