New consulting relationship with GreenTecAuto begins
What actually goes wrong with the batteries????
A look at todays Hybrid and EV battery packs
Battery packs exposed
Keeping Warm In New England
Plugging into the SUN
50A 600VAC transfer relay
AC source transfer relay is finished
Adding some new batteries
All weather dish movers
Almost ready to wire things up
Assembling the parts for the load manager
Beating on the system/ use it or loose it
Better solar absorber plate
Better Specific gravity instrument
bringing in the batteries
Burgers are better
California or bust! Solar modified mobility scooter
Canning pot
canning season is here again
Concentrate the heat test #4
Connecting battery bank #2
Cooking some hotdogs
Crappy luck with the weather
Designing a simpler and lower cost solar tracking amplifier
Equilizing the batteries
Everything is working again.
Finally installed
Finally nearing completion of the battery enclosure
multytracker 1
First test
Getting a BIG solar plug
Getting some experience with DC
Getting started on the final wiring
Getting too old to be slinging 120 lb batterys into the rack
Giving the batteries a workout
Hot water tank as energy storage component test 1
Hot water test 2
Identifing the wires, and mounting the Inverter panel
Insulated hibachi reaches baking temperatures
keeping the head cool
keeping warm.
Sue Dabrowski (my better half) makes some solar eggs
Lightning the super fast EV minibike
Looking the data
Main structure of battery rack is finished
Making some stewed tomatoes
making the connection to the existing wiring
making the DC pos buss bars
More improvements to the dish
Multy purpose tracker 1
New tracking amplifier
No more throw away batteries please
Not very encouraging test # 3
Old Rear projection TV lens makes solar furnace
power distribution box fabrication
preparing to connect the big loads
Reading Specific Gravity accurately
running off grid all day
Running on batteries
Second test
Snow melt prep for test 2
Snow melt test one A close look at the process
solar cell adhesion test #1
Solar cells on my Insight ????
Solar cooker gets some wheels
Solar cookout in 20 degree weather
Solarfest 2013
Solarfest is next weekend so it is time to tweak the tools
Solar powered wood burner X-Y stage
Solar powered wood burner focus and lens assembly
Solar teaching toys
Solar tracking with no electronics" Solar Puppet"
Starting the rewiring
The 7 foot circle of sunlight moves to rear deck.
the final high current connections
the finished load center and charge controller connections
the heavy lifters arrive
The new batteries are finally installed and working
The snow is returning???
The snow keeps on coming, need to figure out a good way to keep the panels clear
The sun is dropping 1KW/SQ meter
The transfer relay is wired in and working.
Tracking the sun Big Time
Mikey's solar panel snow sweeper
Vertical and horizontal trackers installed, drive wheel controls
Very interesting heating element
Who pulled the plug?
Wood burning art ?
Yuck, more snow
Making a small solar concentrator
Building MIMA and the plug in adapters
Converting a telephone truck to electric
DIY dual pulse Capacitor Discharge Spotwelder
Chevy Bolt EV joins the family
Getting in shape while making electricity
Replacing gasoline with solar electric lawn equipment
What is Genesis One?
How to stop the aging process DIY
MIMA Install Day 2005 a Big Success!
Building a hybrid car grid charger
Tapping into the Wind
Expanding MIMA with the Distribution board ( users projects )

Getting too old to be slinging 120 lb batterys into the rack

Getting too old to be slinging 120 lb batterys into the rack
Mikey the old man battery needs custom battery hoist

Ok, I made a nice rack for the battery's, but the batteries are so heavy that I am afraid that I may wreck my back loading them onto it. I can lift them and stand straight, but that only gets them half way to the height required to clear the lip of the big angle, and the top support rail only allows ~ 1/2 inch of clearance, so having full control of the weight at all times is required to pass the rail and get the battery in the rack. After looking at transmission lifts and other off the shelf solutions, I decided that I needed to design and build a custom lifter to do the job.
Went digging in the stuff box, and found a nice worm gear right angle Dayton gear motor which has a very high gear reduction, some ball bearing conveyor rollers, and misc shafts and square tubing.It is important to have a worm drive so the weight of the battery does not back drive the motor. I can lift it precisely due to the high gear ratio, and when I stop, the battery just stays there.
The top rail for the lifter clips into the rear rail of the stand, and the motor driven shaft is set at an angle so a wire rope can be dropped past the top rail on both sides. Made some clips that the battery handles fit into,with offset cable attachment points so the battery stays level so the hoist can be simple clipped on the battery handles.
Getting the battery to the best starting height is accomplished by a custom table that jacks into my big hydraulic jack.
The rope handles on the batteries allow me to grab one of the handles from the inside of the rack top rail, and the trolly lets me move the battery within the stand. I put it down, grab the other handle with the hoist from inside the top rail of the stand, and then easily move it to the final resting position.
It works well, Took 2 days to build,and 8-12 years from now when I have to start replacing batteries(optimist), and am 75-80 years old, I will really appreciate this tool.
(feedback)The lifter worked very well,with all of the batteries being put in place on the rack in ~ 1.5 hours. I developed a technique that allowed me to put the battery in place so only a single lift was required to get it in the rack.

Need to enclose the rack with plywood and make a lift up cover, and I will be ready to plug the new batteries into the system.