Electric Starion EV – Electric Car Conversion – Part 4

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 …
Video Rating: 4 / 5