Wired up, but not moving yet!

I finally have the truck completely wired up but I have a controller problem.

The light on the Curtis 1238 controller blinks a yellow light, which I think is good. But after pressing the accelerator the red light blinks and I read a code 47.

The 1238 manual has code 47 as an HPD sequencing fault and lists the following possible causes:

1. KSI, interlock, direction, and throttle inputs applied in incorrect sequence.

2. Faulty wiring, crimps, or switches at KSI (Key Switch Input), interlock, direction, or throttle inputs.


Also the Set/Clear conditions are:

Set: HPD (High Pedal Disable) or sequencing fault caused by incorrect sequence of KSI, interlock, direction, and throttle inputs. 

Clear: Reapply inputs in correct sequence

Is this the way I have something hooked up, or is this a programming problem that will require having the controller reprogrammed?

I posted this in http://www.diyelectriccar.com/forums/showthread.php?t=187057

I need to figure this one out so I can see the motor spin.

Mounting the Curtis Controller

The Curtis controller provides the AC for my motor and that is the next step in my build. To mount the motor I decided to use some 3/16 flat aluminum stock that would sandwich in between the controller and a nice finned heat sink.

I also needed to weld some aluminum angle onto the flat stock to give it rigidity and a mount point to mount the whole assembly on the motor mount. 

This is what the heat sink / mount looks like as I welded it. You can see the welds are done in 1" sections and then the stock is allowed to cool to prevent warping. I also clamped the heat sink onto the assembly while I welded in order to minimize warping.

Welding the angle aluminum to the flat stock

After welding the tray, I clamped it onto the motor mount that I had fabricated for the motor. Then I cut out a template from cardboard to get the right angles for the angle aluminum for the braces.

Cutting a template to fit for the braces.

I then cut the aluminum braces with a skilsaw fitted with a metal cutting blade.

At this point I have the tray clamped to the motor mount and ready to accept the metal braces. I still need to weld flat ends onto the braces in order to bolt them to the tray and the motor mount.

Electric Motor

I found an electric motor on ebay that should work for my truck. I was told that it is an AC-46 motor.

AC-46 with shaft keyway and C face drilling and rear cover

Aluminum Heat sink for cooling controller

Curtis 1238-6501 Controller with programming for motor

The total was $2800. This was from Allan Bullock out of Livermore, CA



This is a picture of the motor mated to a transmission from a Ford Ranger.

Here is the motor all mounted in the truck.

Back to Square One

Well, I didn't like that heavy motor and CNG equipment in my truck. So I pulled it out and sold it. My new plan is to put in an Electric Motor and do a conversion.

So here is the truck sans motor again.

Engine Dropped into Truck

I finally got the Engine into the 56 Ford Truck

But now I'm having second thoughts about this engine configuration.

Here's what I need to do:

1. Get the steering linkage to clear the exhaust manifold
2. Cut out and modify the firewall to fit the engine (Distributor Hits).
3. Get the exhaust system to route properly
4. Get a gas tank that will fit properly and connect it to the engine.
5. Get the CNG tank to connect to the engine
6. Mount and connect the computers
7. Brake system connections
8. Cooling system connections
9. CNG wiring connections
10. Airconditioning system connections
11. Power Steering system connections
12. Battery Mounted and connnected
13. Transmission driveline
14. Transmission Linkage
15. Transmission wiring.


All this and I feel a bit overwhelmed.

I'm thinking about throwing away the engine and starting over with a 80mile range electric system.

Donor Engine

I decided to do something different for the engine for the truck. It's a Chevy 350 (5.7L) from a 2000 3/4 ton utility truck that ran dual fuel. Yeah that's right. I am planning on putting a CNG motor into this old truck.

This setup has a 4L60E automatic transmission.

It will be a lot of work I hope its worth it.

Corvette Front Suspension

As stated in my previous post, I was afraid that the Volare front-end that had been installed in my project truck was not a good solution.

It looked like it was put in wrong. So using a plasma cutter and a grinder I cut that mess away and sent it to the recyclers.

Then I ordered a front corvette suspension kit from Flat Out Engineering.

This was not cheap because on top of the kit, I had to buy the corvette suspension from a salvaged corvette.

But now the front suspension problem is solved.

Now to put in the engine and set up the steering.