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Homemade 100 HP Motor Controller for an Electric Car

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Step 1: Get/Make a power board and control board.

You are going to need a control board and etched power board.  The power board needs to be at least 3 ounce copper.   Ebay is a good place to look for heavy cheap copper clad PCB.  For example:
http://cgi.ebay.com/25-shts-Copper-Clad-Laminate-FR-4-060-9-x-12-3oz-/310244821519?pt=LH_DefaultDomain_0&hash=item483c084a0f

You could print the picture from this link and somehow transfer it onto a piece of heavy blank PCB, and etch it with a dremel if you have a ver y steady hand.  The dimensions are 8"x6".  This link also has the G-code that you can use to etch with a CNC mill or you could give the G-code to a machine shop.
http://ecomodder.com/wiki/index.php/Open_ReVolt/Fab_Files

Picture 2 and 3 below is an example of an early power board I made with a Dremel.

You can get a control board from me or you can make the control board in your favorite PCB layout software using the schematic here::
http://home.cogeco.ca/~tkooistra/Cougar_Controller_Rev2C_Schematic.pdf
And here are some pictures of the PCB layers:
http://home.cogeco.ca/~tkooistra/bottom_layer_rev2C.pdf
http://home.cogeco.ca/~tkooistra/top_layer_rev2C.pdf
http://home.cogeco.ca/~tkooistra/component_layer_rev2C.pdf

A predone control board is Picture 1.

Pictures 7 and 8 are the power board top and bottom.  The 8 solder spots are just where vias were added.

Once you have the 2 boards, you can go to step 2. 
 
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