October 2008


The second set of gas struts were installed today. The first 12″ of
bed lift is a bit easier, and that helps my back. But above 12″ the
bed lifts itself without my help very quickly. I used a 150 psi and a
130 psi strut on each side. With that much pressure on each side the
bracket had to be mounted a bit better. I also made new 1/4″ thick
brackets that moved the struts in right next to the frame for maximum
tire clearance.

The drivers side guide pin is no longer mounted. The weld nut that it
was screwed into got punched out as I let the bed drop the last 12″
too fast. I’m not sure if I’ll try and rework it since the bed feels
like it will hold itself down fairly easily with just it’s own weight.
I still like the guide pin idea as it keeps the bed more stable. I
will revisit this task after I get other stuff done first..

Lower strut is the additional 130psi unit.

Lower strut is the additional 130psi unit.

A longer bracket had to be machined to keep the struts away from the tires.

A longer bracket had to be machined to keep the struts away from the tires.

Strut mounts on Frame. Frame was tapped and nyloc nuts added..

Strut mounts on Frame. Frame was tapped and nyloc nuts added.

The video chips have arrived. The LCD is handling the info just fine.

So far the Lithium and the Nicads are staying within 2 degrees C of
each other under driving conditions. The lithium might be a couple of
degrees higher during charging.

The bench test with only one cells shows everything is ok. I need to
connect up two more cells on the bench to see that it works as if it
were in the truck. Once bench proven, I’ll install everything into the
truck.

Take a look at the charger board. It has a 13 pin connector on it with
a harness that leads to the connector at the back-center of the main
board. Notice the pattern of the wires in the charger connector.
(1)–(4)–(7)(8)-(10)(11)(12)(13). The dashes are empty. Start
counting from the position that is closest to the front of the truck.
Add 1 amp, 250vac fuses to positions 1, 4. Then add 1/4 amp (any
voltage)fuses to positions 7, 8. One and four is the AC voltage going
to the main board. Seven and eight is the pwm that goes from the main
board to the charger.

The last 1 amp fuse goes to terminal #19 in the junction box. If you
look at the schematic you can see which side to add the fuses to. Some
say the side with the tiny gauge wire. But when I do mine I will be
adding it to the side with the pair of large gauge wires. One wire of
the pair comes from the 12v aux battery, the other wire goes off to
the Magnecharger.

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