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PriusPlus-Mechanical

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Revision as of 02:41, 24 December 2006 by Cewert (talk | contribs) (cleaned up and added measurements to battery tray instructions)
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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

Approx. Time Requirement: 10-12 hours

Tools needed
  • Metal Drill Bits: 3/32, 1/8, 5/32, 7/32
  • Hacksaw with metal blade (or other method of cutting 1/8 inch aluminum)
  • Drill or Dremmel
  • Drill or Dremmel press recommended
  • Metal file for filing rough edges.
  • 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)
Assembly Steps
  1. Cut 4 sections of the 1/4" aluminum channel iron to the exact length of the batteries minus (should be 7 1/16 inches.) Having the batteries actually present is important for measuring. A total of 16 of these peices will be required for all 4 trays.
  2. Lay out 5 batteries and put the 1/4" aluminum channel irons between the batteries. Measure out the length and cut 2 sections of the aluminum angle irons to the length of the batteries (should be 16 5/16 inches.) A total of 8 of these sections will be required for all 4 trays. See photos below for how to layout the pack.
  3. Layout 5 batteries with the angle irons from above and measure the width and cut the 2 end peices (should be 7 1/4 inches.) A total of 8 of these peices will be required for all 4.
  4. Lay everything out on top of a peice of plywood and double check measurements with batteries set in the tray as shown below. It is important that the end peices are under the peices that run along the length of the tray.
  5. Screw down blocks of wood around outside of the frame as shown to hold the outside angle irons exactly where they are.
  6. Remove the batteries one by one and put in pieces of wood where the batteries were to hold frame and aluminum channel irons in place. This jig will hold all the pieces together while drilling.
  7. Using a small drill press or preferably a Dremmel drill press, drill 2 3/32" holes into each corner (or probably only one if using 3/4" angle irons.)
  8. Once the holes are drilled, remove the top angle iron (the 16 5/16 inch one) and using a 1/8" drill bit, widen the holes so that the #4 screws can pass through them freely (only do this on the longer angle iron, not the bottom!) Then counter-sink with a 7/32" drill bit so that the screw will sit flush in the aluminum (see photo below.)
  9. Put in #4 self threading screws. The screws should grab into the smaller angle iron and hold the angle irons together firmly. The screws will stick out the other side.
  10. Using a cutoff attachment on a Dremmel (or a hacksaw, but Dremmel works much better), cut the screws off. Then grind them down flat using the cut off attachment on a Dremmel or a bench grinder.
  11. Re-insert the finished angle iron frame into jig, and place channel irons in place. Drill 5/32" holes at each end.
  12. Using a pop-riviting tool, insert 5/32" aluminum rivits into the channel irons from the bottom and tighten.
  13. Repeat 3 more times for a total of 4 trays.
Photos

Battery Box Top

Approx. Time Requirement: 10 hours

Tools needed:

  • Metal Drill Bits:
  • Chopsaw with metal cutoff blade very helpful (must be capable of 45 degree angles.)
  • Drill
  • Metal file for filing rough edges.
  • Dremmel
  • Cutoff attachment for Dremmel

Tips:

  • If you are buying a new metal cutoff blade for an existing chopsaw, make sure to get one that is large enough to actually cut all the way through the metal with your specific chopsaw.
  • Aluminum blades with small teeth do not seem to work well for cutting through 1/8 aluminum angle irons! They grab and tend to throw the saw and are almost impossible to control. Don't attempt an aluminum cutting blade with teeth on a radial saw!
  • A hacksaw can work in place of the metal cutoff blade, however it is much more difficult to get straight cuts, even with a metal guide for the hacksaw.

Parts needed:

Battery Box Mounting

Approx. Time Requirement:

This section needs writing.

Final Install of Mechanical Parts

Tips

References

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