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PriusPlus-Mechanical

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Revision as of 06:25, 16 December 2006 by 67.184.99.141 (talk) (→‎Battery Trays: Added photos)
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Click show for a short list of the current PHEV conversion and kit options for the Toyota Prius.

For Prius conversion details see the Prius PHEV article and comparisons table.

  1. Ron's Original PriusPlus History and current Contactor Based PriusPlus documentation for DIY projects.
  2. Ryan's PriusBlue is the testbed for DC-DC PFC Based PiPrius kits and documentation for DIY projects.
  3. Toyota OEM Prius PHEV and Prime Could use some work on this page
  4. Enginer China. But the rest of these appear to all be defunct as of 2020?
  5. |~- Hybrids-Plus USA/Colorado/Li -~|~- EnergyCS USA -~|~- Hymotion USA/Canada -~|~- Amberjac UK. -~|~- EDrive USA -~| Peter mentioned Plug-In Conversions |~-

--={ Project Overview }={ 2007 Maker Faire }={ Theory }={ Instructions }={ Parts List }={ RawData }={ Latest News }=--
--={ Doc Process }={ Mechanical }={ Electrical }={ Electronic }={ Interest }={ Talk:PriusPlus Main Discussion }=--

--={ Historic }={ Battery }={ Schematics }={ PseudoCode }={ Photos }=--

Team Photo from the PriusPlus conversion of Sven's Prius from Nov 2006.

This is the home of the PRIUS+ PHEV DIY (Do-it-Yourself) documentation. These pages are currently anonymously editable, which may change in the future. Please feel free to use the Discussion page for general discussion and commentary on the main article. If you would like to add to an existing section use the "edit" link near that topic's heading. Don't forget to use the Summary field to describe your changes. While editing use the "Show Preview" button to make sure your changes look like you expect them to, before you click "Save Page".



Intro Paragraph here maybe with a link to the main PriusPlus article, links to external sites can appear as formatted CalCars, just plain URLs like http://www.calcars.com, or fancy references such as that in the next paragraph.

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Mechanical Sub Parts List

    • Air vents in tire well - This is a quick project that you can do to your car today. 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.)
    • Battery box base (Tom)
    • Battery trays (Tom)
    • Plastic parts mounting board (Little Jim)
    • Anti arc mounted to contactor - You will need a (identifying terminology here) capacitor part number (#) and solder one side to a “ ” ohm resistor and a matching length of wire to the other side of the capacitor. Once this has been completed cover the exposed wires with shrink wrap. Finally, crimp ring connectors to each end and solder in place for a better connection. (Add photo)
    • Heating pad power boxes (Ron, can this now be shrunk down to a single three outlet box?)
    • Charger mounting
    • Battery box mounting (Tom)
    • Power cord mounting (Little Jim or Tom)
    • Kil-a-watts meter mounting (Little Jim) Isn’t this just plugged in?
    • Amp meter mounting (Ron is the amp meter still needed? Should we put this as optional?)
    • Diagnostic LEDs mounting - Use Velcro to mount it just inside the glass door under the radio. To run the ribbon cable, open up the dash and run a cable as shown it this diagram. (Make and add diagram.)
    • V4 Screen mounting
    • CAN-View mounting
    • Prius disassembly and reassembly

Mechanical Sub Parts Construction

Battery Trays

All necessary cut aluminum pieces for 4 trays
Tray set together with batteries
Tray parts laid out
Place wood around tray frame
Inserting wood blocks to hold aluminum
Inserting wood blocks to hold aluminum
Holes drilled in aluminum
Finished corner with screws in

Approx. Time Requirement: 10-12 hours

Tools needed:

  • Metal Drill Bits: 3/32, 1/8, 5/32, 7/32
  • Hacksaw (or other method of cutting 1/8 inch aluminum)
  • Drill or Dremel
  • Drill or Dremel press recommended
  • Wood saw
  • Pop riviting tool
  • Grinder (either an attachment for Dremel or bench grinder)

Parts needed:

  • Aluminum material
    • Either 3/4" or 1" by 1/8" thick aluminum angle iron (2x 8 foot sections, 1x 4 foot section)
    • 1/4" Aluminum channel iron (1x 8 foot section, 1x 4 foot section)
  • 32 5/32 thick, 1/4 inch grip pop rivits
  • 32 #4 flat head self threading screws at least 1/2 inch long
  • Small piece of plywood for making jig (optional, but makes things easier.)
  • Small pieces of wood for making jig (optional)
  • Wood screws (optional)

Step 1: Cut 8 sections of the aluminum angle irons to the length of the batteries. The lenght is (Fill in length here!).

Step 2: Cut 16 sections of the 1/4" aluminum channel iron to the length of the batteries (fill in length here!).

Step 3: Layout 5 batteries and place 1 1/4" aluminum channel iron between each battery as shown. Then cut 8 sections of aluminum angle irons to the exact length of the pack.

Step 4: Lay everything out and double check measurements with batteries set in tray as shown.

Step 5: Lay everything out on a peice of plywood and screw down wood around outside of the frame as shown

Step 6: Remove batteries one by one and put in pieces of wood to hold frame and aluminum channel irons in place. This jig will hold all the pieces together while drilling.

Step 7: Using drill press or Dremel drill press, drill 2 3/32" holes into each corner (or only one if using 3/4" angle irons.) Then, remove top angle iron and re-drill hole with 1/8" drill bit, then counter-sink with a 7/32" drill bit.

Step 8: Put in #4 self threading screws. The screws should tightly fit and hold the angle irons together.

Step 9: Using a hacksaw or cutoff attachment on a Dremel, cut the screws off. Then grind them down flat using a cut off attachment or bench grinder.

Step 10: Re-insert angle iron frame into jig, and place channel irons in place. Drill 5/32" holes at each end.

Step 11: Using pop-riviting tool, insert 5/32" aluminum rivits and tighten.

Final Install of Mechanical Parts

Tips

References

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