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by Aerowhatt
Sun Jul 22, 2018 6:58 am
Forum: Modifications & Accessories
Topic: Supplemental cooling for the charger.
Replies: 38
Views: 813

Re: Supplemental cooling for the charger.

Beginning to look like bonding a finned heatsink to the case with the air blowing over it and perhaps some means of extracting that trapped hot air under the rear deck might be indicated ... jray3's initial list isn't looking that far-fetched. :geek: Yeah, I don't think a heat sink is in order. It ...
by Aerowhatt
Sat Jul 21, 2018 10:22 am
Forum: Modifications & Accessories
Topic: Supplemental cooling for the charger.
Replies: 38
Views: 813

Re: Supplemental cooling for the charger.

OK . . . so does this make sense? Looking back at the numbers the lowest coolant temp and case temp numbers were both achieved with aggressive air cooling the charger case only. If the coolant temperature is lower then the components that Kiev has just pictured on the aluminum heatsink (troubleshoot...
by Aerowhatt
Sat Jul 21, 2018 9:54 am
Forum: Modifications & Accessories
Topic: Supplemental cooling for the charger.
Replies: 38
Views: 813

Re: Supplemental cooling for the charger.

While driving, the waste heat loads should be higher, yes, but there is more than just the radiator fan at work. The turbulent air in our motor bay has to provide some cooling as well, compared to the hot stagnant air during a recharge. I'm just glad I never got around to making that rear belly pan...
by Aerowhatt
Sat Jul 21, 2018 9:52 am
Forum: Modifications & Accessories
Topic: Supplemental cooling for the charger.
Replies: 38
Views: 813

Re: Supplemental cooling for the charger.

During the course of dismantling jay's charger i discovered that the 'clear' plastic sleeving and black heat shrink tubing on the inductor and transformer wiring had somewhat melted and fused together. i don't know at what temperature that would occur, but it is likely greater than 360 F. i've neve...
by Aerowhatt
Fri Jul 20, 2018 6:16 pm
Forum: General Technical Discussions
Topic: Seized Gearbox
Replies: 11
Views: 1229

Re: Seized Gearbox

seismic seems to have left. Bummer. Anyway, I'm dropping the car off at the mechanic on monday and he will give me a quote / fix it if its not too costly. I will let you know how it plays out. Thanks for keeping us in the loop. It's valuable information that should get recorded for others who run i...
by Aerowhatt
Fri Jul 20, 2018 6:11 pm
Forum: Modifications & Accessories
Topic: Supplemental cooling for the charger.
Replies: 38
Views: 813

Re: Supplemental cooling for the charger.

JoeS wrote:BMU case (sits on top of Charger): 95°F (35°C)


Do you have a picture of the charger setup in the 2012? It sounds different than the 2014.

Aerowhatt
by Aerowhatt
Fri Jul 20, 2018 5:58 pm
Forum: Modifications & Accessories
Topic: Supplemental cooling for the charger.
Replies: 38
Views: 813

Re: Supplemental cooling for the charger.

There must be much more heat generated when driving the car, cooling the motor and the inverter - I can't believe the cooling system that handles that cannot handle the charger alone. In your tests, do you think you were moving as much air through the radiator as the stock cooling fan would? If the...
by Aerowhatt
Thu Jul 19, 2018 5:47 pm
Forum: Modifications & Accessories
Topic: Supplemental cooling for the charger.
Replies: 38
Views: 813

Re: Supplemental cooling for the charger.

There is an OEM fan on the radiator at the front of the car - Any thoughts on just making a mod to use that fan? Many ICE cars have 12 volt cooling fans behind the radiator which are energized using a thermal switch on the radiator tank - When it gets hot enough, the fan comes on for long enough to...
by Aerowhatt
Thu Jul 19, 2018 10:02 am
Forum: Modifications & Accessories
Topic: Supplemental cooling for the charger.
Replies: 38
Views: 813

Re: Supplemental cooling for the charger.

Aerowhatt, what did you pick up as your fan's 12v power source, activated only during charging? Right now it is temporary, separate 12 ah AGM. The DC to DC output is right there and easy to connect to. The negative will go to ground (likely to the bracket for the blower). Fuse (3 amp) right at the ...
by Aerowhatt
Wed Jul 18, 2018 6:54 pm
Forum: Modifications & Accessories
Topic: Supplemental cooling for the charger.
Replies: 38
Views: 813

Re: Supplemental cooling for the charger.

I don't think it's been proven, yet, that there are thermal issues -- only that greater cooling is possible. But, what matters is what temperatures are in spec for the components, not whether they're hot to the human touch. I've been charging EV's for clients for 18 years. Recommending and installi...

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