Hills and Vallys

So far, this whole project has been very fun! I've taken my time, researching my system design, talking with people, and taking apart my conversion vehicle. Unfortunately, this is really the easy part. Come the arrival of my parts, i'll be faced with the somewhat daunting task of adapting and installing.

My biggest concern right now, very well may be the adapter. Although I've found a premade solution, i'd rather not pay the price, as tempting as it may be. Beyond this piece i'm not all that concerned with connections, mounts, relays, etc. But fabricating a secure connection from the motor to the transmission is daunting. The completion of the next few steps will very well dictate the timeline and success of this project.


Sooner than I imagined, the time has come to order parts. I've been spending an absurd amount of time, late in the evenings, to research and finalize my system design. Some are locked down, with a few variable I'm still undecided on. Today, I bit the bullet, so to speak, on a few major components!

1 NetGain Impulse 9 motor
1 Iota DC-DC 55A converter
1 Tyco Contactor & Micro Relay

From here, I can begin making my rear mount, and further contemplate the motor-transaxle mount...Purchase or Fabricate...decisions decisions. Although placement of the Iota is a rather small detail, I'll at least feel better having it in my hands.

The next big move is to decide on my Controller. I've begun a discussion here regarding the decision. Although people are trying to be helpful, I still haven't gotten the reassurance I'm looking for. Giving time time as always proven itself for me. As I mull these numbers and ideas around in the back of my head, I find the decisions to work themselves out on their own. As I posted in the Forum:

"Originally I was shooting for the KDH14650B, 144V 650A/260A controller.

Now, i'm thinking i'm better off all around, reducing my system voltage to 120V (or less) and using a controller with a higher amp rating such as the KDH12100B 120V 1000A/400A

This came up for 2 reasons really. 1: i'm all for over rating my controller, for safety's sake and 2: I like the idea of having "higher performance""

In short, I'm still leaning towards the KDH12100B, and running 9-10 12VDC Trojan T-1275 batteries. I suppose this is a typical James mentality of "less is more."

Gas Tank and Exhaust Removed

I guess this makes post 3.

First off, a few images from cleaning the other day:

As for today, i took a few hours this afternoon to remove some of the last remaining parts of the car: The Exhaust and the Gas Tank....

The exhaust was rather simple, considering I just installed it 6 or so months ago! No rust, no seized bolts, just a little pressure on the hangers and she dropped. The Gas Tank, however, was a bit more of a difficult task...not so much to do, but to do alone and not quite empty. All in all it was a success. I'm SURE I've spilled more gas trying to change a Fuel Filter, than i did removing this tank. 'Nuff said!

I'm simultaneously shocked at how fast this project is moving along, and how quickly i'm going to need to finalize plans and order parts. I took a little breather this afternoon and began to collect myself and my parts. I laid out all my un-replaced nuts and bolts, cleaned a few things that are going back in, and overall made sure that I'm not moving too fast for my own good.

Then, I was paid a surprise visit! Didn't get much done after that...washed up, off to dinner and a recording session.

A bolt a day keeps the gas away

I started my day today, first with an espresso, then some engine degreaser. I took an hour or so to spray down my engine bay, scrub the dirty corners, push it outside and hosed her down.

Later in the afternoon, i had an extra hand to take off my clutch and flywheel...

Current Progress Part 1

So, some of you may have heard that I'm building an electric car. Yes, that's right...I'm building an electric car.

Its a little late in the evening for me to make any progress on the car itself, so i thought i should take a change to set up this blog, and start my documentations....

It started a few weeks ago, actually, when I nearly didn't make it home from my trip to Burlington, VT. My 1993 Toyota Tercel was on its last leg and had some serious troubles going on. Needless to say, I made it home and re prioritized buying a new car. Within a 2 weeks, I picked up a 1998 VW Jetta, and the time had come for my long awaited electric car project;

About 2 years ago I started dreaming up the idea, researching plans and parts, trying to understand what was so difficult with driving an electric car...Turns out, I wasn't missing anything. It really isn't all that complicated, and I truly think that anyone who really wanted to do it, could. So I am here, leading by example.

Nearly immediately after purchasing my car, the gears began to spin any I found all this energy I didn't even know i had in me. I formulated a plan, while carrying out step 1, which was to make room for the project.

I cleared out all the patio furniture, sorted through 20 years of junk, made a dump run, installed a stereo, hung a work light, and uncovered the workbench. And within a few days, I was ready to pull in the Toyota with her last few puffs of gasoline.

Considering the time i had, i needed to get some things done, but didn't have the block required for the engine just yet, so I ripped out the back seat and the trunk and began some minor cleaning on "day 2."

Another busy work week went by, and managed to get bunch of research done, finalizing parts and asking technical questions or current EV owners. Come the weekend, I began to pull out the engine, and sure enough, she came out.

My brain is a little foggy to get the exact dates of these days right now, but its been the past 3 weeks or so, with removal, research and cleaning. Tomorrow I will begin degreasing the engine bay and transmission, as well as removing some remaining extraneous parts ( fuel filter, wire harness, etc. Evening plans may even include ordering parts!