Electric Starion EV - Part 5 - at the Electric Car Show
The Electric Starion is now at a drivable state and we take her for a spin at the annual electric car show in Sydney. Some say that by international standards, the AEVA show is probably not a huge event, but conversely, for a small population, there is a high proportion of interest in EVs in Australia plus R&D attracting international attention, despite little interest from the government to date (although the recent Climate Ready initiative may change this). Many types of makes and models of new and old cars converted to electric drive were on display; regular daily commute vehicles, sports cars, classic cars, electric bikes, roadsters, hotrods and even a Formula 'E' race car. The 'H' word was well and truly overshadowed by 'full EV' and many people were interested in how to get their own fully-electric cars. There was one vehicle, a Prius with a K2 battery pack for extended range; these are small lithium phosphate cells up to 3200 milliamp hour, banded together into modules to make up the required voltages and they have a high energy density and handle a high charging current, ideal for regen braking. There's a test review which explains this better, at http://zeva.com.au/tech/K2/ and from there a link to the K2 Energy site where you'll find a video comparison of the cobalt and phosphate impact penetration test. As for my Starion, with an adjustment on the Curtis trimpots, it drove well, gear changing was minimal (we tried 2nd and 3rd starts (and not game for a 1st start test yet) and essentially we're convinced that I'll only ever need to drive in second or third gear as there is so much torque in the Kostov. Reverse gear exhibits a typically higher torque (not as high as first), and as seen in many EVs reversing will have to be handled carefully but further refinement will be looked into, and all in all, the Starion drove like a regular car - a regular Starion in fact with all the handling (including drift test) expected in a sports car. There was no noticeable increase in weight and the batteries delivered the power quickly as expected. We're still a little ways off completing the project as there is calibration to do, incline tests, road compliance and a couple of areas that need respray, some minor body fixes and so on. Overall though, very exciting. Apologies again for the shaky camera, there were so many people bumping around (and a Nokia N93 is not that noticeable compared to the larger cameras the media had), and I really should write a new piece of music (hope this old one's okay). Keep watching http://electriccarsforeveryone.com for updates and Nathan's http://www.converturcar.com website for news and info on upcoming vehicles to convert.
Electric Starion EV - Electric Car Conversion - Part 7
Getting seasonal obligations out of the way, this video should be near the
last we're doing as the car approaches completion. There's a brakes and
air-con/pwr steering test, Nathan talks about water boilers used to cool
engine bays in cold climate countries that could be used for cabin heating
in an EV, I talk a bit about IGBTs and Nathan does a tacho send test using
an IGBT. Sooner or later there may be motor speed controllers custom
designed for EVs that use IGBTs. These things have freewheeling diodes, and
from my limited understanding that means they're there to stop reverse
current voltage spikes across the inductive load. When the current flow to
an inductor is suddenly interrupted, the inductor attempts to maintain the
current by reversing polarity and ramping up the voltage to maintain the
flyback. Without the diode the voltage can go high enough to damage the
IGBT. The diode allows the reverse current to flow through it and
dissipate. IGBTs could be cool things to use for 'electric Boost' -just like a turboBoost. From the video you can also see the BMS
installed - these will be sprayed with conformal coating for protection.
Most of the scenes in all the videos have been shot on a Nokia N93 which
has been very handy. Thanks to Nathan, Linda and Christina for the filming.
And sorry about the seasonal sillyness.
Electric Starion - Electric Car Conversion - Part 6
After successfully testing the drivability, it's back to the workshop to
get stuff removed to paint the battery racks and sort the best place for
the charger and finally add the tacho sender to the gearbox adaptor plate.
The fuel port assembly is done now also; I cleaned up the inner rubber
mount and gasket-sealed the hole with a rubber bung where the original fuel
inlet was, and Nathan cut out the new hole for the power through to a new
fascia plate where the 20A connector will be mounted. A shut-off switch is
added which is essential when 'filling up'; some folks use micro switches
like the ones in arcade machines in their EV fuel ports but we're using a
brake switch which will be more durable and it's long thread allows us to
fine-adjust the profile of the switch so that it triggers properly when the
fuel door is opened/closed. An annoying short had to be traced under the
dash (oops, I forgot to ground a 5W resistor), and you'll meet our little
helpers at the end of the video. Cuuuute...
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.
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 ;-)
#4) Project ForkenSwift electric car conversion: it's legal!
http://www.ForkenSwift.com - Overdue (but waaaay under budget) the car is
now registered as an EV and is legally on the road.
Project ForkenSwift is an electric car conversion made using parts from a
Suzuki Swift, Geo Metro, Baker electric forklift and a golf cart.
Electric Car Conversion Motor Installation
Interested in building your own electric car or how about converting your
gas-guzzler into a 100-mile per gallon equivalent (referred to as MPGE)
electric? Watch as John and Xander install an electric motor in a dune
buggy. John also explains about adapter plates and motor couplings. For
more information please visit: ElectricCarConversions.biz
Starion production car racing Amaroo Park 1986
Starion production car (GroupE) racing from Amaroo Park in Australia 1986.
I used to prepare the silver Starion (No64) owned and driven by Des Gibbs.
Note: Amaroo Park no longer exists it is now a housing estate.
95 Chevy Corsica, Electric Vehicle - EV (fully electric car)
Ive been working on this project for almost 1 year and spend a lot of time
and money with it I was planning to add another 6 batteries in the trunk,
however, I am really short on money right now and cant afford it. But the
vehicle has a lot of trunk space and would be very install the batteries to
increase your range.
The 6 batteries located in the engine compartment are new; I bought 6 Dual
purpose Deep cycle marine batteries from AutoZone. The batteries are in
VERY GOOD CONDITION, LIKE NEW and should last many years.
I drove this EV and was able to get it up to 55 MP/H (or 88 KM/H). It
drives very nice and smooth without any problems. When this car was in its
early development stages, I had to make a decision between performance and
range, so I tried to balance it. This 72V system was designed to work with
12V batteries (six in the front and six in the back) but I havent added the
6 in the back.
Most people choose manual transmission for their EVssince I didnt have a
donor car with manual transmission I designed everything to accommodate
that. I kept the original torque converter in the transmission, but the new
owner can pick new torque converter that requires less spin of the motor to
lock it making the acceleration better. But for me it drives fine as it is.
This is only optional.
I am sorry, but I dont have any other information on the motor. I measured
about 7 inches diameter and about 14 inches long. (Not counting the shaft)
Its an Advanced DC Series Wound Motor.
I havent driven this car until the batteries are drained so I really cant
tell how far it will go. I got about 15 miles and the 72V bank was reading
72.1 Volts. I started with the reading of 78.3 volts. The batteries are not
broken in yet, it will increase overtime. There is only 6 batteries right
now, once the new battery bank is set in the trunk, range should increase
dramatically. (the battery bank in the back should be connected in parallel
with the front battery bank, increasing the amperage capacity, but keeping
it at 72V)
Charging Time: 2-6 hours (depending how much you drove before charging) the
battery bank is small, and if you drive down a few miles only, it charges
up in about 1 hour or so.
Top Speed: 55 MHP (on straight road) Ive had this EV as high as 55 MHP, but
I live in the city and only drive around 30-35MPH
All the electrical parts, such as headlights, blinkers, stop light, reverse
light, high beams, etc are working properly.
The instrument cluster was completely re-done to fit this EV. I wanted to
give a factory look so I kept everything as factory as possible. When you
look at the car and even when you get in You wont notice the difference
until you start driving it.
Ive added 2 digital meters to monitor the two 12V batteries and 72V battery
bank. I custom made the new dash to incorporate the words System Engaged
when the vehicle is turned ON and also put a charging indicator in blue
letters (lit when plugged) so you dont drive away when the car is plugged
in) they are very visible even in daylight.
The interior is very nice and clean (but please, expect normal wear and
tear), the mats and seat covers are new. The back seat could use a seat
cover as well, but its not bad.
I never drove it with more than the driver and one passenger. But I am sure
it can take 2 passengers in the back.
I drove this EV for more than 100 miles so far, it drives really nice, but
there is a little difference while driving an EV. For example when you
stop, the electric motor stops as well, so if you are on some type of
incline, you have to either keep the motor running at low speed (which is
not recommended at all, waists energy!!!) or press the breaks while you
accelerate a bit so the car wont start moving back. But you get used to it
after a few miles.
The tires on the EV are ok, with about half life on them.
The body of the car is in very good shape for a 1995 car. There are some
fading in the rear bumper, a ding in the passenger side door and a dent on
the drivers side door right by the mirror. The drivers side door mirror is
off, looks a little bent, I dont want to pop in place because I dont want
to break the plastic around it. Its working just fine and you can adjust
I added two 12V fans on top of the controller to keep it cool during
driving. Both fans come on and off as the car is turned ON and OFF.
Prius EVMODE Electric Only Option
A must have Prius Accessory. Prius owners, improve hybrid mpg: activate the
factory ev mod option for electric only mode. Known as EVMode or EV Mod
allows you to switch to electric-only mode for increased fuel efficiency
and performance up to 34mph. Easy installation with no wire cutting
Chevy S-10 Electric Vehicle
Robert Green of DIY Electric Car interviews Craig Dusing about his Chevy
S-10 EV Conversion.
144v Trojan Battery Pack
9" ADC Motor
Filmed on 9/19/2008.
For more info, visit: http://www.diyelectriccar.com
My partner Rod is a rally driver and here is a little roll, ahem, two rolls
into a gully on a recent rally event, recorded using his el-cheapo
dash-mount camera. With such damage all looks lost, but fear not...