This is a long one so settle in and read on to find out if we were successful in installing the electric engine.
Ok, Finally after spending several days of attempted hand sawing (no shore power on a mooring) and killing drill batteries by drilling through the bolts in the collar that was hell bent on leaving the prop shaft, I prevailed.
Funny, even after preparing and buying a second drill for the daunting task that lay ahead, guess what was missing? Go ahead, Guess. The friggin charger! Needless to say there were many setbacks during the process but the first step (probably the most difficult) had been accomplished.
I managed to drill through 1 1/2 bolts that clamped the collar tight to the shaft and had to hammer it off after my drill died. Off she came.
From there the next steps were fairly painless. The new propeller shaft collar was put in place. ***NOTE: Do NOT push the shaft back to far.*** Motor was mounted along with the gear reduction unit. Mounting the entire unit to the ground was super simple since there is no need for engine mounts (little vibration). I just simple drilled one pilot hole into each side of the motor runners (that is what I call what the motor mounts to because I like to make up my own names for stuff sometimes). Luckily most are just wood underneath fiberglass. I just ran one fairly thick lag screw on each side to hold the motor in place. I believe they were about an 1″ – 1 1/2″ long.
Next step I started applying the heat transfer grease onto the back of the heat sink which the Sevcon controller will be screwed into. I used my finger instead of a roller like they suggest because they give you a very small amount. I think using the roller would have absorbed it all and left me with nothing. A little extra would have been nice.
My plans were to mount the controller flush against the wall, but after consulting with Thunderstruck, they suggested mounting it on its side long ways top to bottom. This allows for better air circulation allowing the heat to rise away from the unit easier.
Do not place the relay switch under the controller as it creates a good amount of heat.
Next I just watched the Thunderstuck wiring video and got that all taken care of easy enough. I ended up placing the 4 group 27 batteries where the gas tank was for a nearly perfect fit. I am using wet cell batteries for now because they are cheap, but will most likely switch to AGMs in the future.
Installing the throttle cables gave me a bit of an issue. As hard as I tried, I could not get my current wire/lever assembly to give me the play I needed to get full throttle power in both directions (after fabricating throttle actuator-aluminum rod for cable attachment).
My intention by purchasing the Curtis ET-134 was to use my exsisiting cables so I wouldn’t have to mount the funny looking clown nose throttle lever anywhere near the cockpit area. The thing looks like a toy. I lost this battle, but I do intend on either covering or topping off the rod with something cool to distract from the cheesy red plastic knob. I really don’t like the thing.
Anyway, the existing throttle cable(s) were completely bypassed. ( They would have needed to be replaced anyway). The throttle is completely controlled digitally by the Curtis unit ,and yes we now have full throttle in both directions. Although I managed to install it backwards so forward is reverse and reverse is forward. But hey, it works and I am beyond ecstatic. It is now time to bring her home to St. Augustine. Let the move begin!
Until next time,