DIY Plug-In Hybrid Car

 by bennelson
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Step 5: Circuit Breaker and Outlet

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With the generator working, I now need a way to get power OUT FROM the generator.

Even though the generator already has it's own built-in circuit breaker, it seemed like a good idea to have a separate one.

In the RV repair manual, it always showed the power from the generator going to a power center or main breaker box in the RV.

I bought the least expensive breaker box I could at the hardware store, and a single 20-amp breaker. I also picked up an outlet and box to mount it in.

I screwed the breaker box and electric outlet box to a piece of plywood. I then mounted the outlet in the box and installed the cover.

In the car, I mounted the electrical panel vertically to save space. This also faces the electric outlet to the front of the car. For additional rolling testing, I can have the Kill-a-Wall right there to see how many watts the charger is pulling.

The plywood is mounted upright with steel angle brackets, and a triangle of plywood on the end for cross-bracing.

The power cable from the generator feeds through the top of the box, with the hot wire going to the circuit breaker.

I did some early testing on the work bench to confirm everything was working right. An electric space heater makes a swell electrical load.

 
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