Removal of existing leaf board

[doobedoobedo]

Any tips for getting the screws holding the original board out?

I've managed to move a couple but even then they seem to seize up again after about a mm of travel out.

[johu]

They are held in with locktite. About 30% of the screw heads came off on the 2 boards I removed. At least when the head's off you get the board out.

[doobedoobedo]

Yeah just got one out, one sheared half way out, and I've mangled a couple of heads despite hammering the screwdriver bit into them. Thermal mass is too great to use heat effectively. It's blue loctite for anyone else who reads this, applied over 7mm of thread.

[doobedoobedo]

Board is off! I had to drill out all but 3. The one that sheared half way and two I could remove. Hopefully with some heat and a pair of mole grips I'll get the stubs out.

[e^2]

Has anyone applied heat to remove the screws? I have a gen 1 inverter here and I'll try it out.

[doobedoobedo]

I guess it depends on how you're applying heat. The screws are go into a large aluminium casting which will soak it up like anything. I found drilling the screws out I could then detach the casting, apply as much heat as I deemed necessary (blow torch) and fairly easily then remove the stubs.

[e^2]

Thanks. I got this Gen1 inverter as well as a Chevy Spark inverter to play with. Was going to convert one for DC control and the other for AC. Maybe this weekend I can get the Gen 1 apart and see if mine looks like what you all have.

[doobedoobedo]

Mine's Gen 2. Gen 1 is laid out differently - good luck!

[johnspark]

Maybe press a soldering iron onto the middle of the philips head screw, once the screw is hot screw it out? Being careful not to scorch anything else that might be important such as a wire pressing against a screw etc.

[arber333]

Maybe press a soldering iron onto the middle of the philips head screw, once the screw is hot screw it out? Being careful not to scorch anything else that might be important such as a wire pressing against a screw etc.

That is exactly how i took out screws from Volt main board connectors. I used hot air station though. You can clearly see when solder changes state, so be ready with screwdriver .

I also effectively took out dual row connectors. You have to be carefull while rocking connector back and forth and heating it upside down. Normally it just falls down when disturbed enough.