Full Electric Car Home Conversion - 1988 Pontiac Fiero Part 1
The process of converting my Pontiac Fiero to 144 volt electric car. Full video documentation of the process along with a few test drives. It runs on 12, 12 volt Trojan deep cycle lead acid batteries. Powered by a 9.1 in. dia. Advanced DC motor with a 500 amp Curtis controller. Part 2 and 3 will be coming soon. GO ELECTRIC!
Fiero electric motor transaxle first test
This is a major milestone in my 1986 Pontiac Fiero electric car conversion
project. After numerous delays getting the correct adapting hardware for
the new motor to the old transaxle, we finally mounted the clutch and motor
assembly onto the transaxle and frame of the car. With everything in place,
I applied a regular 12 car battery to the motor and amazingly, it ran
without a hitch! See my website (www.roboticmayhem.com) for more
information on this project.
ELECTRIC CAR - Part 1
It isn't really a complicated process to do an electric car conversion, but
you will need to obtain certain specialized parts.
You will need: an electric motor, deep cycle batteries, a controller, a
battery charger, an adaptor kit, and various other small parts.
But first, you are going to need a vehicle that you can do your electric
car conversion with. Any vehicle can be used for this project, but some
work better than others.
Heading the list are small cars and trucks, as they are light and strong.
Your first consideration as shown in the detailed plans is to find the
lightest vehicle that will still do the job of hauling you and whatever
cargo you carry around.
Next, you will want a large DC motor that will produce power for your
electric car. The larger the motor, the more power your electric car will
Don't worry that it will be slow either. Many people have the wrong
impression of electric cars; they accelerate as fast as any vehicle on the
road and travel at least 50 mph.
What about batteries?
You will need to locate about 16-20 deep cycle batteries for your car as
well. The plans outline sources of batteries, even free batteries that you
can find with a little effort. The same source will probably have free DC
It's just a matter of asking.
Why do you need this many batteries? In order to achieve a range of up to
100 miles on a single charge.
A controller is needed to fix the amount of current flowing from the
batteries to the motor which determines how fast you go. The controller is
connected to your old gas pedal linkage for smooth control of the vehicle.
In order to charge your batteries between trips, you will need an on-board
battery charger. That way you can just plug it into any common AC circuit
and get charged up again.
Doesn't this sound like fun?
Isn't it time you got started on your own conversion project?
Kaylor Kit Electric Motor Demo
This is a video of our demo flick for our Kaylor Electric Conversion Kit
for the older VW platform. This is an older style Starter/Generator
Military Shunt DC motor with a custom made adaptor plate and flywheel from
Kaylor Energy Systems. These are no longer being made but can still be
found. We are testing a modern PWM electronic controller specifically
designed to run these special motor. They are able to do regen too. This
motor can push a stock steel bodied VW Ghia to 62 mph with 12 6 volt
batteries. It is a 72 volt system. It works perfect. Perfect for a nice fun
all electric buggy. Or Bug or Ghia.
Dual Motor Electric Vehicle Drivetrain With Powerglide 2 Speed Transmission Walkthrough by EV West
Here's a brief 10 minute video that gives a nice overview of the EV West 2
speed Powerglide transmission that runs without a torque converter direct
drive to 2 coupled Warp 11 motors. Depending on the voltage and current,
these twin motors can put out well over 1000 lb/ft of torque, and 600+ horsepower. We used
this motor and transmission combination to power our BMW M3 to the summit
of Pikes Peak in 2012 setting an all time record for street legal electric
cars. The strength and reliability of this system is key. For more
information regarding this bolt in drive train, please visit
http://evwest.com for the latest updates.
Electric Starion EV - Electric Car Conversion - Part 3
Welcome to the third installment. It's taken a bit of preparation time,
which is essential rather than diving in to find something we've done is
not quite right - both Nathan and I have been guilty in the past of making
stuff only to discover a better way of doing it. But parts availability has
been the biggest issue; delivery time has been long delayed for many
reasons too complicated to discuss here. In this video we re-assess engine
bay mounting; most of the battery racks are welded up now and the battery
management has arrived (except the master unit, d'oh!). We discuss battery
management, the most efficient use of space in the engine bay, as well as
the AC motor we received that will drive the air-con/power steering. (btw,
the AC motor and BMS come from www.bev.com.au where they are custom-made).
Also an older previously unused segment stripped in about removing weight,
as this is crucial in gaining mileage. Oh, and a mention of power cabling
which we will try to get through some of the sub-frame rather than running
under the vehicle or lumping under the carpet (as the power cable sits
inside a plastic flex conduit roughly an inch diameter), so long as it's
legal which we'll check with someone who knows (guessing it's something
like 600mm distance between u-clamp affixing). The Zivan will sit in
trunk/hatch area to the left near the charging 'fuel' port; not sure about
tire placement yet, but it looks like we'll keep our back seat which is
good thing (and did you know that there is an under-seat sub-frame area
roughly two inches high? Hmmm... possibilities....). As for the battery
tank at rear, we're looking at ducting hot air from it using PC fans and
'Exhaust' steel piping. It'd be nice
to get them through the side vent follies on the pillars, but this would
mean a lot of work (they'd probably be part-exposed in the interior, angled
down rather like roll-cage bars). Overall I would have loved to have
progressed a bit more than we have but there have been circumstances beyond
our control and parts supplies have been an issue all the way along - which
in a sense is a good thing so we don't rush too-obvious solutions that
would otherwise cost in time/energy to undo (in a circumlocutory sort-of
way ;-) ). I'd like to thank Christina for her camera work during the
making of these videos, shot on a two-year old Nokia N93 still going
strong, as well as Linda for filming the air-con motor, without them I'd be
stuffed for making videos about this car.
Tesla Motors - The Future of Electric Cars [Full Documentary]
An interesting documentary on Tesla Motors - The Future of Electric Cars
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#1) Project ForkenSwift electric car conversion: 1st powerup
http://www.ForkenSwift.com - First power-up of the freshly installed
forklift hydraulic pump motor in our beer budget, low speed, Geo Metro
electric vehicle conversion.
Project ForkenSwift is an electric car conversion made using parts from a
Suzuki Swift, Geo Metro, Baker electric forklift and a golf cart.
Electric Starion - Electric Car Conversion - Part 2
It's been a long wait, but the Thundersky lithium 144v 160Ah batteries
finally arrived! Now we have to set about determining the best
configuration for the batteries in the engine bay and rear tank using info
from convertyourgasguzzler.com. A bit annoying the BMS modules haven't
arrived yet as a confirmation measurement of the height of these would help
in determining the battery rack height dimension. We could arrange the
engine bay battery racks as a typical square-finish configuration, or
perhaps angled around the motor for a cool effect, and then as Nathan
suggests place plastic clear Perspex sheets over the top for a neat finish,
and tinted perspex surrounding the Curtis terminals too perhaps - we want a
neat engine bay! Nathan mentioned someone who had Thunderskies mounted on
their edges (sides) but the efficiency was greatly deteriorated and
batteries leaked! I don't know if those were the LiCoO2 (we're using
LiFePO4), either way we'll install close to vertical anyway and a crude
animation is included to show possible mounting. Another 'fun' part in this
video was removing the dash so we could access the ventilation system box
and put in the heater core (I know, could have gone with a water micro
boiler unit but budget is getting tight; maybe later); biggish job but not
too hard for two people working on it (Stephanie did it once, alone, and it
was a pig of a job she said). I'll help Nathan get it back together later
as he moves on to the charging setup and we'll the need the BMS master unit
as well (which also hasn't arrived yet). The Curtis will have a water
cooling block underneath where all the FETs are positioned inside (and
block secured tight with thermal compound between surfaces) and maybe a fan
box on top, if there is room, but the water cooler alone should help keep
the thing under 75 degrees C (a Zilla would be better; can't get our hands
on one for now and they're expensive). The very crude animation of possible
engine bay layout will probably change as we decide the best location for
stuff (pwr steer/air con drive components and compressor, pump motor, hoses
etc) and final battery count front and back. The reservoir for water block
coolant may stay in its original place if the hose length is not too long
to be impractical. Slowly but surely we are getting somewhere now. Sorry
about the shaky camera, some of us have been sick with flu. Sorry about the
boobies too, but hot fiddling with cars ;-)
1984 Pontiac Fiero Supercharged V-8
A 1984 Pontiac Fiero witha blow V-8 stuffed in the back of it...It's street
Legal...I shot it at The Grand Rod Run 2012...CRAZY!!!..check it out!
Full Electric Car Home Conversion - 1988 Pontiac Fiero Part 3
The process of converting my Pontiac Fiero to 144 volt electric car. Full
video documentation of the process along with a few test drives. It runs on
12, 12 volt Trojan deep cycle lead acid batteries. Powered by a 9.1 in.
dia. Advanced DC motor with a 500 amp Curtis controller. About $6,000 for
EV components not including: car, tools, steel brackets for battery box,
12V wiring supplies, new break pads. Tested top speed: 70 mph. Though this
was limited by the road. Preliminary range test: 30 miles without fully
conditioned batteries. GO ELECTRIC!
EV Capri ep4 - Kearon's electric car conversion
Yessir - the car now has a real, bona-fide, 100% genuine electric motor in
We also talk about the intricacies of some of the less-sexy parts of an
Electric Vehicle - the brake vacuum pump, the ceramic heater, the battery
pack cutoff switch and the motor adaptor plate.
New generation light weight batteries for electric vehicles
The new efficient battery packs from Lithium House for electric vehicles.
10 times lighter.
I wrote about my opinions on Electric vehicles.
See that at
make sure you leave comment there.