Testing

Ok so we have decided what we want in our requirement, formulated a architectural design and built using our detailed design. The next task is to do some testing.

Under normal designing we would formulate a test document based on the original requirements but that would be jumping the gun a little in an EV build.The steps are generally;

• Mechanical build and test
• Electrical wiring and test
• Electrical systems test with some controlled power applied

The mechanical testing in this case will be checking all components are secure and any interfaces are correctly aligned. Turning shafts by hand is a easy check looking for tight spots and listening for any thing that sounds rough. Make sure there is no power in the system, the prop taking off unexpectedly would really put a dampener on your day! The motor has very little frictional drag so it should be easy to turn the prop. Quick note here, some outboards use a water pump, impeller type, mounted behind the propellor. If your donor leg is this type remove the plastic impeller or it will pump water up and over your electric’s.

Next check your wiring, batteries disconnected at this stage. Batteries should always be easy to isolate, this can be done with a BRB or big red button type isolator, or with a Anderson type plug. Ensure all power connections are tight and well away from metal mounts and other sources of shorting. Ensure your throttle is correctly polarised and that your start switches switch as per the controllers manual.

Once your happy with the wiring it time for your 1st live test. Make sure that the motor is securely fixed and that the prop is guarded. Ensure the throttle is to the zero speed setting and that you have a full battery pack.

When you 1st plug in you may hear an electrical pop, this is normal. The charger and controlled both contain large capacitors and they will draw a high initial current.

Now you need to refer to the controller commissioning manual but the main caution at this stage will be as the prop is dry do not apply much throttle, only enough to spin the prop then shut down. Out of water the motor is seeing very little load and it would be very easy to over speed the motor.

Well that’s enough hints for now from me. There’s a link below of us testing our drive so enjoy and good luck.

If you think you need a full guide and more help then look out for my book coming soon on EV conversion where this project will be covered in depth.

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