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Unread 08-04-2019, 08:52 AM   #41
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Default Re: Let's see your lithium boxes!

I have 2 winches....front and back. The front is "stuffed" under the cup holders in that giant space of "nothing." The rear one is bolted to the cross bar behind the rear seat.
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Unread 08-25-2019, 09:25 PM   #42
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Default Re: Let's see your lithium boxes!

PingEye3, where did you get the diamond plate cut and do you have specs, supplier, cost? I have a TXT but the middle battery separator goes all the way across. Looks like you have a little tab and cut the diamond plate to fit it nicely, did you cut the battery separator and leave a little bit to lock it in place? I am also seeing foam or something to close off everything else in other posts is that pipe insulation or is it something else. Thanks.
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Unread 08-26-2019, 08:49 AM   #43
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Default Re: Let's see your lithium boxes!

Quote:
Originally Posted by seadogger View Post
PingEye3, where did you get the diamond plate cut and do you have specs, supplier, cost? I have a TXT but the middle battery separator goes all the way across. Looks like you have a little tab and cut the diamond plate to fit it nicely, did you cut the battery separator and leave a little bit to lock it in place? I am also seeing foam or something to close off everything else in other posts is that pipe insulation or is it something else. Thanks.
I've seen it in stock at Home Depot and Lowe's.

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Unread 08-26-2019, 10:23 AM   #44
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Default Re: Let's see your lithium boxes!

Quote:
Originally Posted by seadogger View Post
PingEye3, where did you get the diamond plate cut and do you have specs, supplier, cost? I have a TXT but the middle battery separator goes all the way across. Looks like you have a little tab and cut the diamond plate to fit it nicely, did you cut the battery separator and leave a little bit to lock it in place? I am also seeing foam or something to close off everything else in other posts is that pipe insulation or is it something else. Thanks.
I have a local Yamaha dealer (35 yr friend) who is actually an aluminum fabricator as well. The company stretches the Yamahas and provides EMS bodies, handicap carts with ramps, etc, among many other things. I have free open access to anything in the drop pile along with a programmable 10 ' break and shear. That would include the diamond plate and 4 other thicknesses between .062 and .120. That is what I make the pack plates from as well.

Depending on single or double pack is whether I grind the welds to completely remove the T-bar cross piece. Bottom plate is 20.5" x 21.5". If single, I cut it and notch around it. I then have three plates that bolt to the inside back area of the original battery frame to block off dirt from the tires. Yes, the pipe insulation is what you see blocking other dirt points of entry. The old battery frame has 8 holes in the angle, I drop in the plate, mark the holes, drill the plate and then bolt it solid in place.

Latest TXT install plates with power cables / fuse block attached to rear vertical plate. Drop pack in and plug into pack.

Second pic is completed cart. Had an old DCX controller in cart when I started the lithium upgrade.

Last two are of latest RXV upgrade, pack area and rear view with motor.
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Unread 08-26-2019, 12:27 PM   #45
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Default Re: Let's see your lithium boxes!

Quote:
Originally Posted by PingEye3 View Post
I have a local Yamaha dealer (35 yr friend) who is actually an aluminum fabricator as well. The company stretches the Yamahas and provides EMS bodies, handicap carts with ramps, etc, among many other things. I have free open access to anything in the drop pile along with a programmable 10 ' break and shear. That would include the diamond plate and 4 other thicknesses between .062 and .120. That is what I make the pack plates from as well.



Depending on single or double pack is whether I grind the welds to completely remove the T-bar cross piece. Bottom plate is 20.5" x 21.5". If single, I cut it and notch around it. I then have three plates that bolt to the inside back area of the original battery frame to block off dirt from the tires. Yes, the pipe insulation is what you see blocking other dirt points of entry. The old battery frame has 8 holes in the angle, I drop in the plate, mark the holes, drill the plate and then bolt it solid in place.



Latest TXT install plates with power cables / fuse block attached to rear vertical plate. Drop pack in and plug into pack.



Second pic is completed cart. Had an old DCX controller in cart when I started the lithium upgrade.



Last two are of latest RXV upgrade, pack area and rear view with motor.
Beautiful work as always! I should be back in the area in about six weeks.

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Unread 08-28-2019, 06:19 PM   #46
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Default Re: Let's see your lithium boxes!

Finished my 7 module leaf conversion and everything is working great(I even have the regen working so that it feels like my wife's Tesla Model 3).

My cart is an 2014 Ezgo Express S4, and I used 1/2" treated plywood to line the old battery tray. I upgraded to the Alltrax 400 controller, added +/-bus bars and moved as much as would fit onto the new back board. I changed the controller/motor wires to #2, put a new fuse box in, and added the Elcon charger.

Even though it will reduce airflow, I made efforts to seal the wheel wells and other large openings to the cart underside. The Express S4 had big gaps that shot dirt and water up into the battery/controller areas.

Im starting with a 7 pack but planned everything to allow a 14 pack by turning it.

Thanks to all that have posted!


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Unread 08-28-2019, 07:05 PM   #47
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Default Re: Let's see your lithium boxes!

Nice work!! Very clean looking!!
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