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Gav's EV Conversion - Step 18 - The Inspection

It's legal at last! Two tough inspections and a sea of paperwork later, the electric Mitsubishi Tredia is legally allowed on the road! I was as nervous as hell during the inspections but it turns out that it was all worth it as I now have a fully functioning, road-legal electric car! This episode begins with transporting the car up to Auckland City for the main Certification test, then transferring the car all the way back to New Plymouth for the Warrant of Fitness test. Once I had those tests under my belt and a WOF sticker on my windscreen, I could go to the post office and... well, get more forms to fill out. But once I'd filled THOSE out, I was given my registration sticker! Next step was to start my "Road User Charges" (another tax) and away we go - Time to hit the roads! I celebrated by taking the car out for it's first legal go-anywhere road trip! I even passed two gas stations, one of them might look familiar! As always, I welcome your comments and tips. But in the mean time, I'm off for another drive! ;) Cheers!


More Videos...

Gav's EV Conversion 10 - Installing the Motor
The motor is in! After a bit of a delay, the adapter plate has been created and mated to the gearbox, and the motor has been installed into the Tredia! We had a few delays along the way with problems finding an engineer, our wedding being overseas, the adapter plate & motor not fitting in the first time, and THEN having to get a mounting bracket welded up. Whew, there's a bit of work involved in getting the motor installed but at long last it's in! I noticed in the video that we make that heavy motor look light & fluffy lowering it into the Mitsubishi. It is not. I think it was due to editing out all swearing and straining noises from the video. :) I can finally say the motor has been installed into the car and I think a big Yeeehhhaaaa is in order. That's one small step for Gavin, but one giant leap for Gav's EV conversion.

Gav's EV Conversion - 19 - Frequently Asked Questions
Now that the conversion's complete I thought I'd tackle all those questions I get through my inbox. The questions answered in this video are the most common I get asked on almost a daily basis by people at supermarkets, on the street or by email. I'm sure many of you have the same questions too, so on with the video! For all the other technical questions, check out my FAQ page or my Tech Specs page at www.KiwiEV.com I admit, it's not a terribly exciting video compared to the others, but it's important for anyone using my conversion as a platform for their own.

Gav's EV Conversion - 20 - Living with an EV 1
So far so good! Having an electric car has been great! We've been using the Tredia as a reliable daily driver for a couple of months now and we've cleanly clocked up over 800 kilometres (500 miles) already! Our "Unspent Gas Money" jar gets a $40 visit from Her Majesty each week. It's much better having the money we normally spend on gas back in our pockets, that's for sure! After 2 months we've put almost $300 of money in the jar that would have otherwise gone up in smoke - literally. We now have to decide what to spend it on! I've been busy saving money and I've sold a few things to make up enough to buy a new faster charger too. The method I'm currently using works fine, but it's slow and chargers here are VERY expensive. I'm about to order a new Zivan NG3 16-amp charger from EV America! That'll be in the next video, along with my demonstration at the regional Sustainable Energy Expo! So keep your eyes peeled for the next video! Until then, happy motoring. :)

Gav's EV Conversion 12 - Installing the Battery Racks
At last! The battery racks are in! After a some battery choice problems, some battery rack sizing problems and a few delays I've finally got all three racks installed. It took a while and there was many a stressed moment but at last the racks are complete. The rear rack is bolted into the floor with 5mm thick steel bar underneath to hold it in place. The front racks are welded to the chassis (not the sub frame) to ensure the crumple zones remain... well, crumpley in an accident. :) Now it's time to get the control-box and Curtis Controller wired up and visit the bank for the batteries. It's full speed ahead! The conversion will be complete in no time!

Gav's EV Conversion 2 - Dismantling the Tredia
The Electric Car Conversion continues! Following on from my first video a few days earlier, this is where we finally find a way to get the Mitsubishi "Deadia" into the garage. Once in the garage the dismantling begins. We start by removing all the old bits & pieces not needed for an Electric Car. A few examples of now obsolete items I enjoyed removing were: Gas tank Exhaust system Fuel lines Petrol filler spout & lines Used engine oil Oil filter Petrol Filter Carburettor Radiator & lots of brown water And of course, The Planet Killer (the engine)! I have appeased the knuckle Gods many times over the last few days. I have made many a sacrifice of skin and blood to them, as it is written in the knuckle bible. You'll notice I got a big surprise when looking at the gearbox after removing the engine... It wasn't a good surprise either! Enjoy the story as it unfolds everyone.

Gav's EV Conversion - Bonus Video - Wow! I'm Famous!
TV3's top rating current affairs program Campbell Live did a piece on my electric car project! It's a hot topic with the price of gas going up recently, and will get become even more valid when gas prices go up again in the next few weeks. It was a great fun day of filming and test driving on private roads north of the city. You can see some beautiful Taranaki backdrops there too. You can see the presenter enjoying driving the electric car too. He couldn't believe how good the acceleration was and how it didn't use a drip of fuel the whole day! Hey, I'm still getting used to it myself! Being part of the TV3 film crew for a day was great fun - I could do that more often! :) You can check out the next step and project progress on my website www.KiwiEV.com

Gav's EV Conversion 11 - Installing the Heater
There's still a couple of weeks before I can get the battery racks installed, so now's the perfect time to sort out the car's electric heater. It's the law in New Zealand for your EV to have a working heater (primarily to stop the windscreen from fogging up). I was going to buy an EV heater from an EV accessories supplier but was advised I could save a bundle by doing it myself from parts! The whole thing has cost me $70 NZ as opposed to $174 NZ from a popular EV accessories seller! And once again, if I can do it then anyone can! I hope this video proves educational. Feel free to see the install in more detail at KiwiEV.com Once I scrounge enough money together then the Battery Racks video will be uploaded asap! Progress has slowed a little as things have got tight financially so I've even set up a donations page on KiwiEV.com to make sure the car is completed by the middle of summer in February!

Gav's EV Conversion 7 - Buying the Motor
I was worried about this video - I mean how could I possibly make an interesting video about buying a motor on the internet? :) Still, the saga continues! Just this morning I went in to the bank to sign the loan paperwork for the electric motor and borrowed $3000 NZ to get my EV conversion project rolling. This is a major milestone in the conversion process. I reckon I'm about a quarter of the way there already! I made a second trip to the bank this afternoon once the money had appeared in my otherwise sad looking bank account, and sent $2015 US to the other side of the world. Within a matter of a few short days my motor will arrive by airfreight! So, now that the motor is on it's way I can relax right? No... Believe it or not, there are still quite a few things to be done before that motor arrives. Keep watching this space.

Gav's EV Conversion - Step 17 - The Charging System
The car's finally ready for the big inspection! After some initial hiccups, my recharging system is now up and running using 13 individual chargers and one 32-pin plug (I'm only using 28 of the pins though). As well as finally getting the charging system going, I've also installed a splash-guard under the motor and installed the ventilation ducting. Everything went well and each battery is charging as it should with no noticeable voltage-drop through the recharging cables either! A car transporter will arrive in a few days to collect the Tredia and take it up to Auckland where I'll meet it for the big test! Let's hope it passes! (I'll need everyone to cross their fingers) Next video coming soon!

Gav's EV Conversion 9 - Installing the Pot Box
The next video in this classic New Zealand Electric Car Conversion has arrived! My Potentiometer Throttle Box has arrived from America! It was a birthday present from my mum - sure beats socks & undies! This "Pot Box" as it's known, is like a light dimmer switch. The accelerator cable is attached to it and when you press the gas pedal, the lever moves, adjusting the amount of power the motor is to receive. I also learnt that in New Zealand you require an additional spring connected to the outside of the pot-box for safety in case the main spring fails. It made me wonder if other countries have this same extra spring requirement?

My Civic EV Electric Car Project Part 3 Our AC-50 Electric Motor Kit
2001 Honda Civic Electric Car Project. Our AC-50 Electric Motor Kit. Just alittle video to show the components I have selected to drive our electric car down the road. This is a well thought out kit that I have seen in use and have seen relentlessly tested! This exact same kit and others are available at http://www.evtv.me/ Our motor @ 108v at 650a up to 3800 RPM will deliver 121ftlbs of torque and 76hp. Its designed and works best in cars under 3000lbs. Subscribe to Tomswonderfulworld watch and learn as I build an Electric Car.

Gav's EV Conversion 14 - Installing the Batteries
The batteries have arrived and are installed at long last! It took a few days of fiddling about but we installed and secured the front and rear batteries into place with super-strong stainless steel strapping. I also created and installed my sealed rear battery box which has the extraction system connected to the turbo timer and a relay so that both the ignition and the charging system activate the fans. The turbo timer ensures the fans keep going for 3 minutes after I've turned the car off, or unplugged the charger. It sounds complex but it isn't. You have to remember it's ME we're talking about here ;)

Gav's EV Conversion 4 - Cleaning the Exxon Valdez
Visit www.EVsecrets.com & grab my new EV Conversion book + video package! Video number four is here (early too). We're getting closer to converting the car to electric every week! In this video I removed the seats & carpets before scrubbing & hosing them down. The amount of brown water that came out of those seats was pretty gross but at least my fiance will sit on them now. :) I ended up scrubbing the metal floor, door skins and ceiling too and I can finally say the car smells good!

BMW Electric Conversion
Electric Motor Werks converting pre-production prototype. This video demonstrates the key features and techniques of the electric conversion process.

Gav's EV Conversion 6 - The New Gearbox
In this latest episode I take the old internal combustion parts to the refuse centre and then pick up my new gearbox. I found a local wreckers yard that had an old Mitsubishi Cordia gearbox for $150 so I snapped it up right away! You'll notice the new gearbox doesn't have a gaping big hole in the side of it which helps a little... It needs a serious clean up though. Looks like it was beaten with the oilly stick.

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