Yet another long weekend spent working on the car. My wife will be very happy when I finish this project.

The new handbrake cable was fitted and adjusted. Wired the motor speed sensor to the controller and fit a cover to the controller bus bar connections.

The heater is controlled by a solid state relay which I operate from an illuminated switch mounted on a blank plate where the ash tray used to be. It produces a decent amount of heat and I think you could use it to heat the vehicle as well as demist, although it uses a lot of power.

I got to use my new MIG welder to make the battery hold down bracket. MIG really makes welding simple.

I had a final read of the NCOP14 regs to see if I missed anything and it turns out I did. I forgot about the requirement to disable the vehicle while its plugged into a power point. I haven't run any cables from the fuel flap for a switch. However the charger does output 12vdc onto 2 of its control terminals while its powered up. I will use this to operate a relay which will isolate the 12v feed to the contactors. The relay will also drive an input into the BMS master to start the charge cycle.

There is also a clause in the regs about having an audible and visual alarm if the brake vacuum is low. I am not sure what other people have done with this, so I might see if I can get away without it for the moment. It's a bit stupid as there is no requirement for this in the original vehicle.

I drove the car down to the AEVA meeting last week and it was well accepted. I found out when I got there that one headlight (connector disconnected) and both tail lights were out (blown fuse). The automatic worked very well and I was able to drive very slowly into the hall under perfect control. The controller has really good low speed control due to its current feedback loop.

I will be ready for the engineers inspection later this week so fingers are crossed. The final thing before registration will be replacing the windscreen as it was cracked when I bought the car.

I got the charger back from repair installed it and charged up the battery. On the weekend I fitted the power socket behind the fuel flap, wired it up, finished tidying up the battery wiring, fitted some plastic sheet into the battery box lid and fitted the lid.

The back seat was then installed and at first it didn't fit. A piece of trim under the seat was fouling the battery box lid mounting bolts. 5 minutes later after the jigsaw had its way with the trim it all fit
with nothing to spare.

The hand brake cable no longer fits so I took it to ATS Cables to get a special cable made. Thanks to Graeme from Suzuki Springwood for the tip. I will pick it up tomorrow and install it tomorrow night.

This will finish the rear section of the car.

What's left?
Wire motor speed sensor
Fit a cover to the controller bus bars
Fit and wire heater switch and test heater
Make and fit a hold down bracket for the aux battery
Fine tune vacuum modulator push rod length
Fit BMS master into dashboard
Fit Asus EEE PC into dash
Fit warning HV stickers to relevent bits