Pontiac Firefly AKA 'The Electrafly' conversion from ICE to 132V DC Electric
Colin J McCubbin.© 2008/2014 ( Click on any thumbnail to enlarge it. )
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1759

1760
Test fit of bonnet/lamps before final battery box welding.

1761
How do you tell if there is clearance when the bonnet is down and you can't see inside? An old trick. Place a pointed lump of plasticine on any likely high spots, close the bonnet, open it. See how much it squished. I need 3/8" clearance, this lump shows nearly 1" at this spot.

1762
Clearance under battery box to gearbox.

1763
Clearance under battery box to motor.

1764
Clearance behind battery box to bulkhead, new brake line still to be clipped to bulkhead.

1765

1766

1767
To reach the old fuseblock I had to remove the driver's seat and lie on my back looking under the dash... No fun. I'm rewiring the car, so I'll mount the fuseblock where the 12v battery used to be. Manufacturers take note ;-)

1768
Cats cradle time..

1783
With 5 battteries it may be wise to brace the center of that strut tower tie bar. Can't do any harm.

1784

1785
Bolted into the top rear gearbox mount.

1786

1787
Starting to make sense of all that wire.

1788
It fits!!!! Perhaps I can fit a panel between the battery boxes to mount the contactor, 500A fuse and emergency cut off on. Hope so.

1789
The 5K ohm pot box with the old throttle cable fits nicely here, with no sharp bend in the cable. Just got to make a clevis to join the cable to the lever.

1790
Detail of the 5k potbox and auxillary return spring.

1791
Front battery box with mounting plate for the 5k ohm 'potbox' attached. The triangular fillet is for a second 'turn off' spring to cut power/speed if the throttle cable breaks or the potbox return spring fails.


1792
Front battery box showing the front mounting arms. This leaves easy access to the brake master cylinder, servo and proportioning valve.

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