Once the batteries were installed, it felt as though all the hard work was in the rear view mirror. It was still necessary to install the controller and the throttle, but with a little creativity, they rapidly went into the car on a temporary basis. A flat area directly in front of the firewall on the passenger side is intended for the B+ jumper connector. When the black plastic cover of the connector is removed (picture DSC03899), internally there are multiple terminals designed to tie together the trunk located battery, the chassis ground, and the 12+ volt power cables that are located in the hood area.
Picture DSC0517 of the shelf at the passenger side rear of the motor compartment after the battery terminal base had been removed. (updated 8-12-2015)
Picture DSC01520 showing the platform after the tall side wall and the rear bracket had been removed with an abrasive cutting wheel. The smaller edge lip visible in the foreground was maintained to increase the rigidity of the platform. (updated 8-12-2015)
The connector was relocated from the top surface of the metal tray and moved underneath the metal tray. A cardboard template was then trial fitted on the top surface. After adjustments, the pattern was transferred to 1/2" thick plywood, and a final surface of 8.625" x 20.5" was cut. The plywood was then notched at the outboard edge and forward corner to accommodate the plastic trim and the curvature of the adjacent metal surfaces (see picture DSC03871). If this location is determined to be optimum and final, the plywood will later be replaced with Aluminum.
Picture DSC03876 showing one of the plastic nylon spacers (Home Depot) that was used between the plywood and the base of the Soliton 1. These spacers provided clearance between the base of the Soliton 1 and the bolt heads visible in picture DSC03871.
Access to allow marking the locations of the required holes for mounting the Soliton 1 was very difficult, so a sharpie and bolt were improvised to mark the required hole locations.
Picture DSC03872 showing the bolt after it was heavily marked with a Sharpie. The Soliton 1 was then located on the predrilled plywood, the bolt was then inserted and turned with pressure so that the marked bolt tip would leave a mark on the metal surface beneath the plywood. After the Soliton 1 and the plywood were removed, a clear round circle was evident on the metal (Picture DSC03874 with a black arrow for emphasis).
Picture DSC03874 showing one of the marked points that was then drilled to allow the bolts to pass through first a washer, the Soliton 1 base, a nylon spacer, the plywood, the BMW metal chassis, a washer, and finally into the nut.
Picture DSC03878 of the Soliton 1 secured to the plywood platform area.
What next remained was an installation of a throttle mechanism and control switches that would allow activation of the battery pack contactors and then application of 12+ volt power to the Soliton 1. It was felt that to permanently connect the Soliton 1 throttle assembly to the accelerator pedal on the driver's floor would take significant effort and time, thus it was elected to make the throttle a hand activated temporary device instead. At the right of the BMW center console area is a vertical steel structure that was used to secure the position of the console. This steel can alternately facilitate the mounting of a 0.125"thick Aluminum 1.5" x 1.5" x 8" angle. The Aluminum was predrilled (d = 15/32") for three LED lighted SPST switches and a pair of holes (d = 15/64", 3" apart) to mount the throttle (picture DSC03905). It was also necessary to drill a lower mounting hole (picture DSC03906) in the steel structure so that the Aluminum angle would remain stationary (picture DSC03906).
Picture DSC03905 showing the predrilled front face of the mounting surface. The top two holes were used immediately, and the lowest hole will be for future use. The two smaller holes to the right are located to mount the throttle assembly.
Picture DSC03906 showing the side view of the mounted Aluminum angle.
Picture DSC03908 showing the installed temporary control and throttle assembly. The top (blue LED) automotive toggle switch (Radio Shack), when illuminated, indicates that the battery pack contactors are energized and the pack voltage is being supplied to the high voltage inputs of the Soliton 1. The green toggle switch, when illuminated, indicates that 12+ volts is being applied to the Soliton 1 IGN+ terminal, and as long as the Soliton 1 PGND terminal is grounded, the Soliton 1 controller will be activated.
The batteries were not connected to the control system until all the wiring had been checked and rechecked. First for continuity of circuits, and then for presence of the 12+ volts under each of the toggle switches conditions. As careful as I thought I was being, wiring mistakes were still found!! Since no high voltage was in use during the testing, no harm, no foul, no regrets.
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