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 - 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 - 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 ;-)
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 1
Three years ago I knew nothing about cars nor cared for them much, until
Stephanie Walsh got me interested in Starions. Her ex said back then, 'You
gotta know about cars or some mechanics will rip you off'. Sadly, Stephanie
passed away in 2007. I have decided to do an electric car project in her
honour, as she was a wiz at electronics and taught me much in that area
also. Together with Nathan Bolton we are now converting my rare Starion to
full electric drive. This is the first video of a series I intend to do
following the conversion of my car. We now have a Kostov 10.7 inch electric
motor that used to be in an electric bus for the Sydney Olympics. I've got
lithiums on the ship from China, a Curtis controller and other bits and
pieces coming for the air-con, power steering etc. The car has been a
headache in some ways, getting it up to spec, re-spraying in places etc but
overall it should look good when done and will comply with local laws for
on-road every day use. This video covers engine mounting estimations,
rear-battery compartment construction, and Nathan's teaching me to weld
(and as someone commented, "You had better hide your boobs or sparks will
fly' ;-P ). The adaptor plate for the gear box has already come back from
the machinist and in this video we drop the motor in and temporarily
position it to get a rough estimation of available space - there should be
plenty for the controller and batteries, along with a home-designed cooling
block for the controller.
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!)
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.
DW TV Prisma - La Revolución Silenciosa, El auto eléctrico del futuro
El futuro del automóvil se aleja del petróleo y se orienta hacia el
vehículo eléctrico. El auto a gasolina con motor a combustión interna
está a punto de extinguirse.
Tal descubrimiento llega tarde por la acción de diversas burocracias.
En Alemania se puede comprobar qué es lo ofrecen los automóviles
eléctricos en la actualidad, que ventajas y también qué inconvenientes
suponen para el conductor. El coche eléctrico es fuerte, silencioso y más
limpio que ningún otro vehículo.
Algunos preparadores privados ya trabajan por su cuenta reemplazando
motores de serie por uno eléctrico.
Así mismo ya hace mas de 10 años algunos entusiastas guardan desde
entonces, coches eléctricos que en se vendían y que fueron posteriormente
El dilema : la industria vende lo que el cliente pide ??? o el cliente
compra aquello que la industria inunda desde sus factorías ???
El cambio está llegando... con mas atraso del debido, pero llegando
La renuncia (rectificación) de Derechos de autor Bajo la Sección 107 del
Acto 1976 de Derechos de autor, la concesión es hecha para "el empleo
justo" para objetivos como la crítica, el comentario,
el reportaje de noticias, la enseñanza, la beca, y la investigación. El
empleo justo es un empleo permitido según el estatuto de derechos de autor
que de otra manera podría infringir. Puntas(consejos)de empleo no
lucrativas, educativas o personales el equilibrio (saldo) a favor de empleo
Copyright Disclaimer Under Section 107 of the Copyright Act 1976, allowance
is made for "fair use" for purposes such as criticism, comment, news
reporting, teaching, scholarship, and research. Fair use is a use permitted
by copyright statute that might otherwise be infringing. Non-profit,
educational or personal use tips the balance in favor of fair use.
Copyright DW , ZDF
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.
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
#5) Project ForkenSwift electric car: shifting gears
http://www.ForkenSwift.com - Since the car has no clutch, people often ask
how I change gears. The purpose of this video is to show just that.
EV's with more power than the ForkenSwift don't need to shift much - some
just leave the transmission in one gear for city driving, and only upshift
for highway speeds.
The ForkenSwift needs to be shifted because it's a low voltage car with a
low power controller.
So how is it done? With a firm hand and a little patience for upshifts,
and by rev-matching the motor speed to the transmission speed when
There's no need to use a clutch in an EV when stopping or starting out. An
electric motor doesn't idle like a gas engine - it stops when the
accelerator is released and the car stops.
At about 3:40 you see one potential "problem" of driving an quiet vehicle -
a pedestrian steps off a curb - backwards! - into my path as I am slowly
approaching. I don't think he would have backed up right into the car, but
I tapped the horn to let him know I was there anyway. Disaster averted!
(This has only happened to me once in 6 months.)
Full Electric Car Conversion 1988 Pontiac Fiero @coolelectriccar
I created this video with the YouTube Video Editor
Best conversion videos are here
and here http://pinterest.com/CoolElectricCar/electric-car-conversion/
Converted Cars http://pinterest.com/CoolElectricCar/zombie-cars/
"Blur-Song 2", sound recording administered by EMI: 17:09
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.
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