During the drive home, I discovered that the brakes were not nearly strong enough. They looked good while the truck was on jacks, only having to stop the wheel. However, they did not do a good job stopping the truck! Additionally, the clutch pedal broke off (!!) about the time we hit Stoughton. Of course you don't 'need' a clutch pedal, but it sure does help.
I drove the truck to Ellsworth Welding in town and Jeff Ellsworth (who loved the truck) figured it had to be removed to weld. So, I removed it the next day. It was a bit of a puzzle, but came off easily after I figured that one out.
He did a great job of welding, and as a bonus, he reshaped the metal so that the pedals sit much better. They had bent out of shape after all the years of use.
|Notice the brake master cylinder under the floor|
|The pivot is squeezed between the cab hanger|
The other major accomplishment was fixing a software 'bug'. I was having trouble with the truck 'starting'. Sometimes when I turned the key, everything was AOK, and sometimes it would only run the motor for a second before shutting down.
After several e-mails with Jack, I finally found the dopey mistake that I made. You have to tell the controller box which outputs are hooked to where. In my case I have outputs running to the two contactors, the main contactor and the pre-charge contactor. I had them assigned to Outputs 3 & 4, but the wires were hooked to 4 & 5. When it worked, it was just lucky that the output 3 came up in a state that happened to run the truck. It shouldn't have worked at all. So, when I fixed that, everything now comes up and runs very reliably.
Here are a couple of pictures of the controller software. The guys at EVTV, Jack and Colin mostly I think (not sure), did a great job.