Low Power Cables

These low power cables from Hybrid Plugs (see links) are primarily used to connect the PHEV control board to the various relays and fans that will be necessary for paralleling the PHEV battery pack with the OEM pack.

Top View of Battery Box

The battery boxes from Plug-In Supply can be preloaded with High Voltage components if desired. Going counter-clockwise from the upper left corner, this box has a shunt (for current measurements), high voltage contactor relay #1, fingerless fuse holder #1, high voltage contactor relay #2, fingerless fuse holder #2, heat sink with a diode bridge, charger interlock relay, control circuit board, and a low voltage power supply. There are also two cooling fans and one GFCI mounted on the left side of the box. A single battery of the 20 total required is also shown.

Tilting Steel Battery Box

Keeping batteries secure is vital to vehicle crash-worthiness, therefore a well made battery box is a necessity. However, it’s important to note that it’s impossible to know how these modifications will behave in an accident without professional crash testing. Because this type of testing is not available to the do-it-yourselfer, I selected this box because of it’s steel construction. It also has the ability to raise for access to the spare tire. It’s available from Plug-In Supply (see links).

Side of the Battery Box

A side view of the battery box. Here the cooling fans and GFCI outlet can be seen. This photo also provides a good view of the gas spring that will help me lift 300 lbs of batteries.

Charger Mounting Plate

I made this mounting plate to fit on some existing holes in the Prius body. Some welded nuts on the plate his will allow me to securely mount the charger and still easily remove the charge if needed.

Side Fans Location

Another view of the side exhaust fans from a wider angle to give a better idea of their location.

Side Exhaust Fans Installed

A closeup of the side exhaust fans. These fans exhaust warm air out of the car using the existing atmospheric equalization duct on the Prius. A piece of aluminum angle hold them in place.