Electric Polaris Ranger

[Xfaxman]

Do keep us updated, looking forward to seeing how it turns out.

This is the left side battery rack module, still in the crate:

This morning I got the motor controller put back in:

And the right side battery rack module mounting holes drilled and bolted in:

Got the motor cables connected and the left side battery tray bolted in:

 

[rd_macgregor]

How does the volume and weight of the new battery set compare to the old/original?

 

[Xfaxman]

How does the volume and weight of the new battery set compare to the old/original?

Volume under the seat on the driver's side, before:

4 155ah deep cycle lead acid batteries.

After, 1 Lithium-ion battery pack.

Battery weight before, 8 at 90 pounds each = 720 pounds.

Battery weight after, 2 packs at 110 pounds each = 220 pounds.

 

[Xfaxman]

Used the shop crane to put it in on the battery tray, on a 2x4, so I could get the chains off:

Drilled the mounting holes and bolted it down:

 

[JRobyn]

I am wondering if fastening down the battery packs as far outboard as possible might provide the optimum cooling for the Sevcon controller?

 

[Xfaxman]

I have never had any overheating problems, so didn't think about that.

 

[Ford850]

Holy smokes! 500 lbs lighter is a huge difference. I wonder if you'll notice any loss of traction, but gaining 500 lbs of payload capacity is great.

 

[Xfaxman]

I wonder if you'll notice any loss of traction,

I don't think that I have to worry, with the narrow Interco Interforce 27-7.5-14, 6 ply, R1 tread tires:

 

[Xfaxman]

Re: Electric Polaris Ranger Conversion To Lithium-Ion Batteries

Some more progress pictures.


Removed the 2 inch diameter state of charge meter:

Filed a notch on the left side of the hole to clear the plug for the signal cable:

Don't like the way the new one is to be mounted to the supplied block plate. It would not be removable if you believe their claims about the VHB mounting tape. So I made my own mounting system.


Found an old pill bottle. Put the cap on the back of the new meter with VHB tape:

Had a small plastic Black Pepper jar and used an 1-1/4 hole saw on it:

Used the old trick to mark a straight line around a cylindrical object, used a pencil against the left side of the hose clamp:

Cut the bottom off at the required height:

Drilled the pill bottle for a short 6-32 all thread, held in place by double nuts:

Drilled a hole in the side of the retaining device for the signal cable:

Assembled to a piece of cardboard to simulate the dashboard and show how it works, Rear view:

Side view:

Front view:

 

[rd_macgregor]

Wow, I was surprised at how big the difference was between the new and old batteries. If cost was no object, you could double (it doesn't look like triple would fit) the capacity of the new set and still have a lighter load of batteries with considerably increased operating range.