[ausev] Lessons Learned

[Marc Kohler]

Thought I'd share some experiences with the group.  I'm sure many can relate
to these as well as add to this list.
During a recent conversion (still on-going!), I was reminded of the
following.

Lessons learned:
It takes twice as long as you schedule (partly due to you, partly due to
your suppliers).
Inspect every item that comes in, verify the packing list versus shipped
items and versus ordered items, look for documentation, scan and file
original.
Read documentation as soon as possible so that you understand how it's
supposed to work and be hooked up.  Order misc items as necessary.
Draw out the wiring schematic with the new parts added to help create a list
of wiring/cabling/terminal/lug needs.
Little things add up (terminals, hardware, shipping), be prepared.
Use flexible welding cable, not the solid strand stuff from Home Depot.
Find a place that sells nuts, bolts and washers in small quantities (like
Quality Fastener) unless you want to have your own parts bin of spares
(which adds to cost).  Use Grade 8 where possible.  Grainger and McMaster
Carr have good websites but you usually have to buy in bulk.
Get familiar with Mouser (or DelCity.net or Digikey) catalogs/websites.
They will help with switches, relays, ring terminals, etc.  Mouser items
usually arrive the next day (they are in Texas) even when going UPS ground.
Use EV dedicated resources like EVSource.com, EVParts.com, ElectroAuto.com,
CanEV.com, EV-America.com, etc. for one stop shopping for the bulk of your
items.  You may find individual items cheaper here and there but breaking up
into multiple orders can add to the overall shipping costs.  Do not expect
immediate customer service.
Think of the normal sequence of events the user will face, and specialty
events (i.e. servicing, storage).  Design accordingly (allow for easy
disconnect of DC-DC when in storage as not to discharge the pack; design in
access points for servicing if needed).
Purchase extra terminal lugs and cable/wire.  You will make some bad crimps
and will cut things 1/2" too short.
When ordering a Zivan charger, just go straight to the source at Elcon
(Electric Conversions in CA) as few distributors carry stock and end up
having to order it anyway.
Check out Staylonline.com for any electrical connections (plugs/receptacles)
your charger or car might need.
For me, mechanical fabrication (making all the bits and pieces to accept the
new parts) takes longer than the actual electrification of the car.

I better get back to work now but I invite others to add to this tribal
knowledge.
I'm sure the Revolt guys could write chapters with what they've learned.
Marc Kohler