Lithium Conversion (leaf battery)

[rottie]

I finally got some time to work on the golf cart project today. and took a few pictures.
I had to clean the battery acid cancer, then paint. Luckily it was only on the surface and the battery tray was in reasonable good condition.
I had to modify the factory pot box/controller mounting and put a z bend in the throttle rod as the new mounting location is ~2" higher and above the battery tray.
I added aluminum diamond plate over the battery tray as the batteries are different size than the original lead acid battery case and needed a flat mounting surface. I then secured the Aluminum plate to the old battery tray.

I now have a mocked up of the motor controller, main contactor, reversing contactor, DC-DC converter (voltage reducer) and the onboard charger.

I am still not happy with the placement of the reversing contactor, but may have no choice as I could not fit the main contactor and reversing contactor over by the controller, not enough room and sits too high, interfering with the seat. These are BIG relays!!! I also wanted to keep all high current cabling very short to minimize resistance loss.

I still have to mount the main battery fuse, current sense for the BMS and BMS. Then make the new battery cables at 2AWG plus all of the miscellaneous wiring.