Kaylor Motor Install.mov
Kaylor Motor Adaptor Electric Car Kit. This is installed in a 69 VW Ghia.
We are testing a modern controller to power the old Starter/Generator
motors for these Kits. These conversion kits were specifically built for
the old VW platform. They work great but work best on the old fiberglass
Building the Electric GT-40 Electric Car
What one man in one two car garage was able to do to create a car that
didn't use any foreign oil. If he can do it, then the car industry can
too and we can free our children from the bonds of oil.
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 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 ;-)
Full Electric Car Home Conversion - 1988 Pontiac Fiero Part 2
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. Part 2 of 3. GO ELECTRIC!
Electric Cabriolet First Drive
A first drive around the neighborhood in my nearly completed electric car.
This is a 96V ElectroAuto VoltsRabbit kit with 16 6V batteries. Everyone
agreed it was awesome.. Insert "EV Grin" here..
Homemade car - test drive
Homemade car- First test drive after the following:
Completely new steering system
Dual front drum brakes (not hooked up yet)
Almost a complete replacement of some of the frame, engine mount, throttle
and brake pedals, axle, and wheel hubs.
Please note this is, of course, not the finished product and, in the
future, will be receiving body panels, a door, and a windshield in the
style of an early cyclecar.
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.
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.
Electric car conversion by ACPropulsion -- everyday driving of a real EV
The red GOLF was was converted to then-state-of-the-art spiral wound Optima
batteries by ACPropulsion.
Conversion was a team effort, with Paul Carosa doing much of the design and
construction. Alan Cocconi was the chief designer of the the Gen I drive
system and Battery Optimizer modules. Dave Sivertsen did the battery
This is probably the most sophisticated lead-acid battery management system
ever devised, with individual module-level monitoring of sealed
spiral-wound lead-acid batteries that are still available today.
Of course, the best module-level Battery Management System is not quite as
good as the cell-level monitoring of the (successor) T-zero and then eBox,
a system now used on the banked Lithium cells in the Tesla Roadster.
While the Tesla might be considered the third-generation EV1, the Red Car
could be considered the second-generation, perhaps a test article among
that pack, and thus has a place in automotive history.
On the video, the Red Car is compared with two Toyota RAV4-EV, which have
over 100 miles range using NiMH nickel batteries produced prior to the
Chevron lawsuit's shutting down production (Nov., 2002).
But, really, lead-acid is the best choice for the daily commute; the
lead-acid EV1, upgraded to PSB 1260 batteries, had a range over 100 miles,
more than enough for the daily grind even if you didn't plug-in while
The weight of the battery pack, 1300 lbs., in contrasted with the Tesla's
1000 lb. pack, and it's not much more. In fact, lead-acid is
less-expensive and the least environmentally damaging battery, since it's
The Red Car passed a stinky "clean diesel" and shows how it COULD act-out,
although only 100 Amps is used (it can put out up to 500 Amps, for a real
charge on acceleration).
After fixing a legacy solar system (inverter failure), the Red Car heads to
AQMD, which is full of gas IC cars, not clean cars, and has almost all of
the EV parking spots "IC'd" -- blocked by oil-fired Internal Combustion
The AQMD, ironically, was highly involved in the effort to kill the
Electric car, obviously hasn't stopped trying, despite the dirty air in