The following depicts various phases of my Ranger EV conversion. I’ll be adding more in the future. The project is nearing completion. I think will be ready to roll sometime in the early spring with 2 other EV conversions right behind.
My email address: evranger@pacbell.net
My home page: http://home.pacbell.net/evranger
This shows the Kostov beside the custom one piece adapter which I designed and machined. I also designed and machined the coupler from stainless steel and used a taper lock bushing.
As the taper lock tub assembly was drawn onto the motor shaft dial indication of the front face assured perpindicularity. A re-check was done with the flywheel installed at a 5" radius. Less than .002 pk-pk was achieved.
I designed and built a custom tach sensor assembly based on the Allegro hall effect sensor IC. Flywheel was lightened and starter ring gear removed. A small notch at every 120 degrees was cut into the flywheel which is sensed by the Hall effect device. Small circuit board uses surface mount components and drives the existing tachometer directly.
Completed motor to transmission assembly. Motor/clutch assembly easily slid into position on the bell housing.
Motor-transmission assembly installed in vehicle with a few Optima YTs surrounding it.
Rear battery boxes are made from 14 gauge steel folded and MIG welded to form a sturdy box. One bolts to the truck frame rails behind the rear axle and the other ahead of the rear axle. Each carries 10 Optima YT's. 6 more batteries are mounting under the cab and six in the engine compartment for a total of 32 in a parallel-series arrangement achieving 192 Volts nominal.