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?
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 EV Miata MX5 - First FULL POWER Test and Drive
First ever test of the battery electric MX-5 Miata running at full
144VDC/800A. http://acuteaero.com for details, up to date project progress.
This machine is FUN, crazy torque!
FAQ-Top speed: 70 tested (it'll go higher) Range: 11 mi tested (it'll do
more) 0-60: not yet tested. Burnouts: yes. Powerslides: absolutely. Still
not totally finished project- STAY TUNED!
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.
GO GREEN Electric VW Bug Rebirthauto 96Volt Kit #001 in car
Vehicle1975 Volkswagen Beetle
MotorD&D Motor Systems, Inc. ES-31B DC Series Wound DC
ControllerKelly KDH12600 Controller Assembly 120VDC 600A
Batteries8 gpl-3100t , 12.00 Volt, Lead-Acid, AGM
LifeLine Size 31T Absorbed Glass Mat (AGM) Sealed Battery #gpl-3100t
System Voltage96 Volts
Kelly Controller 110VAC by 96VDC AGM Battery Charger
Kelly Controller 96VDC to 12VDC Converter
Top Speed65 MPH (104 KPH)
Range30 Miles (48 Kilometers)
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
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...
Behind the scenes of building an electric car - The journey
Follow us on a journey of the successes and dissapointments that were
Team Swinburne Electric 2010, AKA tse_10, was the first year a group of
Swinburne engineering students endevoured to develop and build an Electric
Vehicle for the Formula SAE competition. The team hit trouble when they
blew up their motor controller, just over a week before the competition.
The team then borrowed another motor controller which also ended up
blowing. The team then borrowed ANOTHER motor controller, to which they had
some success, until the night before the competition, when it also blew up.
In total the team blew up 3x $4,000 controllers, 6 times (after repairs).
It is thought that the motor is faulty and is causing the issues.
Final Year Members:
Non Final Year Members:
Jacob Vu Tran
ATA and MEVIG
Warning: Although edited, this is behind the scenes footage and may contain
some course language and/or offensive behaviour.
Electric Homemade Wooden Go Kart Run 3
Hey guys this is Revision 3 of the electic go kart. It has a new Ramsey
winch motor and a 400amp curtis 1204-410 motor controller. The sprockets
have been upgraded to hold a #35 chain and the new size chain has been
added. I the motor specs: 8000RPM at 24v, 32 in pounds of torque, 45 amps
no load, 140 amps full load 6 hp continuous, 11 peak, running currently at
36v 85amps. Thanks for watching. Please leave your comments in the sectiob
below. Please note: this is not supposed to be professional looking or
super-functionalal for that metter, it wat meant to be a fun project.
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.
Build Your Own Electric Car, Part 1
See more info at http://300mpg.org/
Build Your Own Electric Car: Cheap, part 1, as presented by Ben Nelson at
the Mother Earth News Fair, Sept. 25, 2010.
Nelson shows how you can build your own car on a small budget with no
background in electronics or engineering.
WORLDS FASTEST street legal ELECTRIC CAR
Learn about EV technology: http://www.electric-vehiclenews.com/
Worlds fastest street legal ELECTRIC CAR 1972 Datsun 1200 Whtie Zombie.
This car is based in Oregon... there are something like 18 hydro electric
power plants in that state! Hydro generation accounts for 58% of all
electricity in Oregon (Over 70% in Washington) and coal accounts for less
Only about 15% of the energy from the fuel you put in your tank gets used
to move your car down the road or run useful accessories, such as air
conditioning. The rest of the energy is lost to engine and driveline
inefficiencies and idling. Therefore, the potential to improve fuel
efficiency with advanced technologies is enormous. With an Electric Car it
costs just $1.00 per 100kms with MUCH more performance than with petrol at
$20.00 per 100kms.
EVs use between 1/6th and 1/10th the energy of a comparable ICE powered
Datsun 1200 EV Specs:
- Motor - Hi Torque Electric 'Siamese 8' Series Wound DC Dual Armature 8
- Controller - Zilla Z2K EHV 2000 Amp
- Battery - 60x 16 Ah Hawker Enersys 'Genesis' Lead-Acid 360 Volts
- Final Drive ratio - 4.11 : 1
- Weight - 2,450 Pounds (1,113 Kilograms)