PriusPlus-Mechanical - Revision history

Rjf: {{PriusPlus-Doc_Process|mw-collapsed}}

2020-06-14T12:17:50Z

Rjf: rm dup Category:Prius PHEV

2007-10-09T08:51:33Z

rm dup Category:Prius PHEV

Rjf: Categories

2007-08-28T18:54:59Z

Cewert: /* Air Vents */ classic method only

2007-06-30T18:22:41Z

Air Vents: classic method only

Cewert: /* Electronics Box (Alternative) */ added photos

2007-06-23T15:58:00Z

Electronics Box (Alternative): added photos

Cewert: /* Electronics Tray (Classical) */ name change

2007-06-16T16:23:04Z

Electronics Tray (Classical): name change

Rjf: /* Electronics Box (Alternative) */ closed tag

2007-06-16T15:46:36Z

Electronics Box (Alternative): closed </gallery> tag

Cewert: /* Electronics Box (Alternative) */

2007-06-16T15:45:06Z

Electronics Box (Alternative)

Cewert: /* Electronics Box (Alternative) */ Started section

2007-06-16T15:42:45Z

Electronics Box (Alternative): Started section

Cewert: /* Battery Box Top */ alt. mouting method instructions added

2007-06-10T02:20:37Z

Battery Box Top: alt. mouting method instructions added

← Older revision		Revision as of 12:17, 14 June 2020
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	Intro Paragraph here maybe with a link to the main [[PriusPlus]] article, links to external sites can appear as formatted [http://www.calcars.org CalCars], just plain URLs like http://www.calcars.org, or fancy references such as that in the next paragraph.		Intro Paragraph here maybe with a link to the main [[PriusPlus]] article, links to external sites can appear as formatted [http://www.calcars.org CalCars], just plain URLs like http://www.calcars.org, or fancy references such as that in the next paragraph.

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 [[Category:PHEV]]
 [[Category:Prius]]
 [[Category:PriusPlus]]
 [[Category:CalCars]]

← Older revision		Revision as of 18:54, 28 August 2007
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	=References=		=References=
	<references/>		<references/>
		+
		+	[[Category:PHEV]]
		+	[[Category:Prius]]
		+	[[Category:Prius PHEV]]
		+	[[Category:PriusPlus]]
		+	[[Category:CalCars]]

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 =Installation of parts into Prius=
-==Air Vents==
+==Air Vents (Classic Method)==
 Remove spare tire and the two black drain plugs that sit in the tire well.  You may have to use a dremmel to open the hole so you can drop in the [Delete later-(Ron I think I found a piece of conduit that will flush mount in here. The PVC pipe can be glued to it.  I’ll get you a part number and picture. By doing this a project could be prepped weeks in advance and the spare will still fit in there until the final conversion days.)  ] 2” PVC threaded coupling.  Next connect the 2” 90 deg. Elbow and then a length of 2” PVC pipe per this photo (add photo showing underside of car with both pipes pointing back to the rear.)

@@ Line 227: / Line 227: @@
 [[Image:Electronics Box Alternative.png|thumb|Electronics Box diagram]]
 <gallery>
 Image:Electronics_box_being_assembled.jpg|The electronics box taped together
 Image:Electronics_Box_Partial_1.jpg|Partly populated electronics box
 Image:Electronics_Box_Partial_2.jpg|Partly populated electronics box

@@ Line 217: / Line 217: @@
 * A jig saw seems to work well for cutting the aluminum angle irons
-==Electronics Tray (Classical)==
+==Electronics Tray (Classic Method)==
 [[Image:Electronics Tray Classic.png|thumb|Electronics Tray diagram]]
@@ Line 223: / Line 223: @@
 Image:P10380.JPG|The electronics tray
 </gallery>
 ==Electronics Box (Alternative)==

@@ Line 237: / Line 237: @@
 Image:Fuses_in_electronics_box.jpg|Close up of the mounted fuses
 Image:Electronics_Box_And_Charger_in_Tire_Well_2.jpg|The electronics box with the HV section's cover resting on top
-<gallery>
+</gallery>
 =Disassembling the Prius=

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 * Aluminum material
 ** 1 1/2 inch by 1/8 thick aluminum angle iron (2x 8 foot sections)
-** 1 inch or 3/4 inch by 1/8 inch thick aluminum angle iron (1x 4 foot sections -- may have leftovers from trays)
+** 1 inch by 1/8 inch thick aluminum angle iron (1x 4 foot sections for classic - 8 feet for the alternative mounting method)
 * Corner brackets - can be found at Mennards in shelving hardware section
 * 24x #8-32 flat head machine screws
 * 16x #8-32 nuts
 * 8x #8-32 x 1/4 inch binding posts
-* 1/4 inch Plexiglass or Lexan sheet, at least 33 inches by 18.5 inches.
+* 1/4 inch Plexiglass or (preferably) Lexan sheet, at least 33 inches by 18.5 inches.
 * 4 small non-conductive nylon screw and binding posts (for holding Plexiglass "shields")
@@ Line 181: / Line 181: @@
 # Place 4 batteries in the trays, one in each corner (see photo.)
 # Place electrical tape over the terminals on the batteries to help prevent any arcs.
-# Make sure to leave space for the middle bolt down and bolts for the frame!  (The battery box base isn't finished yet and requires space in the middle!!!)
+# Make sure to leave space for the middle bolt down and bolts for the frame.  (The battery box base isn't finished yet and requires space in the middle.)
 # Set one of the cut angle irons on top of the batteries (be sure not to arc the batteries!)  Place the Plexiglass "Shield" in place and use clamps to it there.  This allows for accurate measurements.
 # Lay the other angle iron with the opposing 45 degree angle out and measure the width & cut with a 45 degree angle (end peice should be about 15 3/8 inches wide.)
-# Hold the angle iron that will be used to bolt down the top to the end of the battery pack (use clamps to hold it on.)
+# Hold the angle iron that will be used to bolt down the top to the end of the battery pack (use clamps to hold it on.)  For the classic mounting method, this is only required on the left and right sides.  For the alternative mouting method, the angles should go around the entire battery box top.
-# Holding the angle irons and bolt down angle iron right where they should be, set the corner bracket on the corner and make sure that it covers the angle iron that will be used to bolt down the battery box!
+# Holding the angle irons and bolt down angle iron right where they should be, set the corner bracket on the corner and make sure that it covers the angle iron that will be used to bolt down the battery box.
 # Mark where the holes on the top of the bracket are on the angle iron (or drill holes if necessary.)
 # Using the Dremmel cutoff tool, cut down the binding post so that it does not stick all the way thought the bracket if set on top (see picture.)