Building the Brains of the HIGH VOLTAGE System - IT MOVES!!

Hey Jerry , I’m in engineering for a EV truck bus manufacturer. I have a few suggestions . 1. EMI shield the power battery cables and the 3 phase cables from motor controller to the controller . At higher speeds you will create alot of noise that will disrupt all your CAN and Cell sampling . You shielded the parallel CAN by twisting the pair but you need to protect them from external emi so you can also shield and ground the low voltage wires . 2. That’s is a great battery design , but I suggest you fill in the sides of the battery box to keep the inertia/vibrations from flexing and breaking the modules case . If your modules flex around inside the casing it will break the bus bars because they are solid copper coated with nickel so no flexing in that material . So basically make it the battery box really snug for the modules .

"We probably shouldn't be doing this, but..." - Every first drive I've ever done.

suggestions: 1-insulate the terminals 2-Put some "cushion" to the batteries on the sides 3-Add a refrigeration system to the batteries

Dude, I have watched nearly all of your videos, and among the entertaining, several of them have really warmed my heart. But this series hits me deeply and makes me so happy: My dad was an electrician his entire life. Highschool dropout and a vet, the guy put himself through trade schools and educated himself on the job to where he had the knowledge to do much of what you are doing and had a dream of putting together his own electric car out of frustration that the big 3 couldn't figure it out. He passed in 2016 and wasn't able to make that happen. He'd have loved to watch this, he'd have loved to lend a hand, and I know he'd have loved to see someone making this happen. Thanks man!

Such an achievement getting the wheels to move. Props to jerry and everyone who is helping him, he managed to turn a vehicle that's not at all designed to be electric and made it so, in his freaking garage!!

2 best pandemic projects on YouTube 1. Zack's humV 2. Colin's tunnel Thanks Zack! Happy new year to everyone!

Hey Jerry, I believe you should cover those terminals with some insulation. The cells may move around and short out on the aluminum box.

As I am a retired (45 yrs. in and as an) Electrorincs Engineering tech Large Sawmill - Headrigs and 500 HP Gang edgers, former USN Aircract Electronics tech (ASW, AT3), USAF AutoTrack Radar tech 30333, USArmy Infantry, I would offer an A+ for what you showed us in this video. Safety was paramount with death so close... great job! I am sure you'll fix the no grommets without me saying anything... you got it to move without destroying your shop. Everyone waqtching what you did should be very impressed. -- Take Care - Radar 71 and still alive Jerry Rigging all the way.

Been waiting for this the whole week, this is the only series that i watch and check the progress bar every 30 sec hoping it doesn't end at all 😂

12:24, careful, blue loctite will eat away at many plastics making them extremely brittle. The product spec for 243 recommends keeping it away from all plastics. "This product is not normally recommended for use on plastics (particularly thermoplastic materials where stress cracking of the plastic could result). Users are recommended to confirm compatibility of the product with such substrates."

the best electric "hummer" project in the world and the only. i cant wait until this beauty finished

You need rubber grommets to prevent the conduit cabling rubbing on the edges of the metal holes. Great video as always, Happy new year !

23:00 - one comment here, you should use thread deforming all metal lock nuts instead of normal jam nuts for your HV connections. Vehicles see a lot of vibrations and these nuts could potentially come loose, but a thread deforming nut is highly unlikely to ever come loose from vibrations. Nylocs don't work because the high currents going through these connections can melt the nylon.

As electrican,i would advice you to put a edge protection around the holes where you put the wires trough,not that the isolation gets damaged on the metal edges when going over bumpy roads.But amazing work,i love it

Just a note: You should be using HV wires with a braided shield, it will decrease the eletromagnetic noise in the car It is also advise to use proper CAN cables

I really like how you have solved many problem even without tutorials for your project. This is real innovation right here.

Must be an incredible feeling to finally get it moving under its own power :)

That 'crusty compound' on the battery terminals was not dielectric. It was a conductive paste needed for high current connections to prevent hot spots in the connections.

It’s been my experience with wiring ( both from my job building sensors for The United States Airforce and my hobby as A Car Audio Freak) That only crimping those pin connections ISN’T enough to ensure they are solid enough. I always go the extra mile and solder the part and the wire. And it’s done because the USAF DEMANDS It to be DONE, not because I want to! And since they have it that way, I decided to do that with my own projects. Haven’t had a single failure on ANY wire connection since. This project is DEAR to my heart ❤️, because my father was involved with the initial development of the HumVee as Commadant of the Ft Eustis, Va Transportation College. I’m so very impressed with your efforts!!

when he said "siiiick" at 30:50, I felt that.