Electric Starion EV - Part 5 - at the Electric Car Show

The Electric Starion is now at a driveable 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.

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Electric Starion - Electric Car Conversion - Part 6
After successfully testing the Starion drivability of the electric car conversion so far, 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...





DIY Electric Car: 05 Transmission Basics
http://300mpg.org/electric-car-instructional-dvds/ Building an electric car, we take a look at the transmission and how we are going to use it for the EV Geo Metro. This video is an excerpt from the BUILD YOUR OWN ELECTRIC CAR instructional DVD. On this project, there's NO CLUTCH! Yep, no clutch. Most of what a clutch does is disconnect the engine from the road, so you don't kill the engine when you come to a stop. An electric motor has no problem simply not rotating when you are stopped. Remember, you typically DO need a transmission in a DIY electric car, if for no other reason, simply to have a good place to mount the electric motor! On a front-wheel-drive car, the differential is also built into the transmission, so it's easiest to simply reuse the transmission to divide the electric motor power to BOTH of the front drive wheels.





Opel Agila Electric Conversion 20Kw part 2 Homemade controller
Specs Motor: Permanent magnet DC motor 230V 207A peak Battery: LiFePO4 72 cells in series A123 Systems 20Ah Lithium 4,4Kwh in total Controller Homemade 220A 300v continuous MC33035 IC Servo-brake: Electric vacuum pump 70w Max Speed: to be tested estimate ~ 55km/h Wh/Km : 56 at 17km/h not 100 % accurate masina electrica.com masinaelectrica.com Website : http://www.masinaelectrica.com





Electric Starion EV - Electric Car Conversion - Part 4
Most of the hard part of cabling through the sub-frame has now been done. The car's been pretty well stripped to the bone but all this work should be worth it. While a lot of EV builders get their cabling to run under the car, protecting it in the sub-frame is my preferred option and this has been checked by the road-legal engineer and so far so good. Metal saddles are used to clamp the conduit flex where exposed, so nothing is loose. The main issue has been space in the engine bay, making sure the batteries sit comfortably under the hood and trying to fit the ancillary stuff. With the laser-cut mounting plate for the AC air-con and pwr steer driver motor etc, orientation had to be decided upon, and the battery placement largely dictated this, so its placement may appear odd at first, but will be very secure when completed. Battery balancing was also performed prior to installation and now we're on the road to re-assembling everything, dash, final wiring etc. I bought some Electrolube DCA200H conformal silicon spray for the BMS PCBs but we'll install and test everything first. Some BMS modules such as the TS-90 have all components protected in a resin block and maybe BEV who build the modules in Australia will integrate moisture protection in a future version. Nathan has done an excellent job welding up the supports for the ancillary drive components and the pulley part I supplied (which I happened upon by chance in my big box of junk in the shed) should do the job well for control. Also, the trunk/hatch area is painted and ready for battery installation. The next video will show the batteries installed with their BMS and the car will be (fingers crossed) basically drivable (with cooling system installed later if time runs out (but we've both got jobs to bring in da regular bux so time has been tight)). Despite some other issues with the car, it should be mostly ready for our annual EV show in Sydney (while down the road the bigger money Motor Show shows off the rip-off complicated hybrids and guzzlers - and we wonder if anything will really change and if governments will really listen (it starts by replacing greed with need but convincing them is a difficult thing)). Check out www.electriccarsforeveryone.com for updates, and I'd like to thank you all for your great support and comments (even the naughty ones are appreciated ;-P ). Oh, sorry re miscount on episode version (working on cars and video's and doing jobs means we're both need a hell of a lot of sleep!)




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