This weekend was full of high power! Lots of work done, many connections made, and all of my components are mounted! There are a handful of connections left to make plus the installation of my rear coil springs:
On the topic of my rear springs, they've arrived. I can't recall if I blogged about it, but I ordered new springs to compensate for the additional weight of my batteries. And, although i'm yet to install them, I am very satisfied with the company overall: coilsprings.com
I was referred to them from another EV guy, Randy. So, i called them up and said:"Hey, I have a '93 Tercel and need to support an extra 900lbs in my trunk." Without a flinch, they replied "Okay, just give me the OEM part #s on the original springs, and we'll have them out to you in about 3 weeks." Even better, it only cost me about $250. Pretty sweet deal, if you ask me.
This week, I'll be picking up a few extra feet of cable, calling the DMV, and renting a spring compressor. Ideally, next weekend, i'll be installing the springs and making my final connections. I may even drive by Sunday!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! Thanks for reading.
Whose that guy
Not "That Guy", but I've gotten another sponsor: The Guy
"The Guy" AKA Christopher Schreiner, is looking for a nice set of wheel for my car. Much appreciated. Take a chance to buy his CD, see him live, or buy him a drink!
This weekend was a productive one. I finally carved out some time in the schedule to get stuff done on the car. Although I didn't know exactly what i was going to do when i started working Saturday morning, I soon work up, and got going...Coffee helps.
I began with what i had on hand, which was my Electric Vacuum Pump that had arrived this past week. After my coffee, i worked out where it was going to go, and proceeded to install it. In the process, I ran into the end of my heater core, which i new had to go, so I stopped installing the pump and began removing the heater core; If anyone has ANY expierence with these, you probably know that it is not the simplest of tasks. In a short matter of time (relatively speaking) I had the entire dashboard ripped apart, and I still scratching my head. Nonetheless, i managed to get the darn thing out. I promptly put it aside and continued to install the pump as i had originally intended. That pretty much wrapped up Saturday, aside from some evening pondering, on how I would complete the next few tasks, which brings us to Sunday:
I woke up with a plan: Coffee and breakfast, NAPA ( 4 ga. battery cable, fuse, terminal, etc), home depot ( 1.5" ID tubing 8 feet ), home + install. Unfortunately, NAPA didn't have all the cable i needed, but i got 10 feet insead of 30. The other 20 will be in on Tuesday. Anyways, i made a bunch of measurements. Connected some lugs on my long High Voltage leads, and proceeded to tackle the heater core. I fortunately found myself in the "Zone" and i was able to weld a pretty decent carrier for my new Ceramic heater core, which fits quite nicely. While i was welding, i figured i might as well go all the way, and i made 1 more battery tray for my accessory battery ( which i had much deliberation on. I didn't even really want to keep it, but there was no real reason to go buying some other battery. I had the space, i just needed to make it work. So i did. Still not 100% cool, but acceptable, more that it was.)
So there it is. I'm getting there. Not as fast as i had hoped, but getting there. If i find any time this week, i may actually have my full battery pack wired, and the car Hot! Whoa, that would be cool. I'm going to need to go back to ABCO for more 2/0 cable to make the final connection to the fuse, controller and motor. So, i'm not quite driving yet, but getting there...
"The Guy" AKA Christopher Schreiner, is looking for a nice set of wheel for my car. Much appreciated. Take a chance to buy his CD, see him live, or buy him a drink!
This weekend was a productive one. I finally carved out some time in the schedule to get stuff done on the car. Although I didn't know exactly what i was going to do when i started working Saturday morning, I soon work up, and got going...Coffee helps.
I began with what i had on hand, which was my Electric Vacuum Pump that had arrived this past week. After my coffee, i worked out where it was going to go, and proceeded to install it. In the process, I ran into the end of my heater core, which i new had to go, so I stopped installing the pump and began removing the heater core; If anyone has ANY expierence with these, you probably know that it is not the simplest of tasks. In a short matter of time (relatively speaking) I had the entire dashboard ripped apart, and I still scratching my head. Nonetheless, i managed to get the darn thing out. I promptly put it aside and continued to install the pump as i had originally intended. That pretty much wrapped up Saturday, aside from some evening pondering, on how I would complete the next few tasks, which brings us to Sunday:
I woke up with a plan: Coffee and breakfast, NAPA ( 4 ga. battery cable, fuse, terminal, etc), home depot ( 1.5" ID tubing 8 feet ), home + install. Unfortunately, NAPA didn't have all the cable i needed, but i got 10 feet insead of 30. The other 20 will be in on Tuesday. Anyways, i made a bunch of measurements. Connected some lugs on my long High Voltage leads, and proceeded to tackle the heater core. I fortunately found myself in the "Zone" and i was able to weld a pretty decent carrier for my new Ceramic heater core, which fits quite nicely. While i was welding, i figured i might as well go all the way, and i made 1 more battery tray for my accessory battery ( which i had much deliberation on. I didn't even really want to keep it, but there was no real reason to go buying some other battery. I had the space, i just needed to make it work. So i did. Still not 100% cool, but acceptable, more that it was.)
So there it is. I'm getting there. Not as fast as i had hoped, but getting there. If i find any time this week, i may actually have my full battery pack wired, and the car Hot! Whoa, that would be cool. I'm going to need to go back to ABCO for more 2/0 cable to make the final connection to the fuse, controller and motor. So, i'm not quite driving yet, but getting there...
Getting EVen closer!
Last night, I was feeling a bit restless, so I headed out to the garage to see what i could get done...
Before i knew it, it was midnight, and i had successfully mounted the Curtis Controller w/heat sink and the DC-DC converter!
I'm still waiting on my charger and Vacuum system to arrive, but its getting down to the wire now ;)
I just place an order with Parts-Express for all kinds of random electrical pieces: wire, relays, fuses, etc. I've also begun to draw up my own EV schematic to plot out what is what and where and how! All in all its looking pretty good, the next few weeks should be exciting. i'm hoping to get some video footage up soon too.
Oh, and i talked to coilsprings.com : Looks like they'll be taking care of the Rear Axle load issue.
Before i knew it, it was midnight, and i had successfully mounted the Curtis Controller w/heat sink and the DC-DC converter!
I'm still waiting on my charger and Vacuum system to arrive, but its getting down to the wire now ;)
I just place an order with Parts-Express for all kinds of random electrical pieces: wire, relays, fuses, etc. I've also begun to draw up my own EV schematic to plot out what is what and where and how! All in all its looking pretty good, the next few weeks should be exciting. i'm hoping to get some video footage up soon too.
Oh, and i talked to coilsprings.com : Looks like they'll be taking care of the Rear Axle load issue.
Coming to form
It has been over three months since i began cleaning the garage, and taking out the ICE engine. And for a minute there, i would stare at the empty chassis, and wonder how this project would every be complete.
Today, I can say, i see the light at the end of the tunnel. The project is moving along very smoothly, although not without hard work and hiccups. I've spent the past two days almost entirely in the garage, measuring, cutting, drilling, welding, repeat...cool...prime...dry....paint, repeat!
I'll spare you the detailed shopping list, but to give you an idea there was a lot of angle iron, threaded steel, nuts and bolts, more welding wire and a new cutting blade...
So, moving forward; This week, I'll be working out the mounting of the controller and heat sink, as well as, hopefully, receiving my charger, cable ends, heat shrink, and some other misc supplies. All that is left is connecting a lot of wires, making those wires, and a few small pieces to fabricate...and some cosmetics. A lot of testing too. oh and did i mention schematics? Yea.
In the end, i now have securely mounted all 12 batteries; 10 in the rear, and 2 up front. Here are some pictures, Enjoy:
Today, I can say, i see the light at the end of the tunnel. The project is moving along very smoothly, although not without hard work and hiccups. I've spent the past two days almost entirely in the garage, measuring, cutting, drilling, welding, repeat...cool...prime...dry....paint, repeat!
I'll spare you the detailed shopping list, but to give you an idea there was a lot of angle iron, threaded steel, nuts and bolts, more welding wire and a new cutting blade...
So, moving forward; This week, I'll be working out the mounting of the controller and heat sink, as well as, hopefully, receiving my charger, cable ends, heat shrink, and some other misc supplies. All that is left is connecting a lot of wires, making those wires, and a few small pieces to fabricate...and some cosmetics. A lot of testing too. oh and did i mention schematics? Yea.
In the end, i now have securely mounted all 12 batteries; 10 in the rear, and 2 up front. Here are some pictures, Enjoy:
more parts...
Another quick update: I placed orders today for my Deka batteries, russco charger, and vacuum pump kit! Just a few more odds and ends togo
And it all fits
Cheers to measuring first!
The motor went in very, very smooth. Almost too smooth. Its amazing how much space is still in there, aside from the < 1cm between the motor's shaft and the wall! Once the motor was mounted, I was busy making measurement to fabricate the rear motor mount. There are 4 threaded holes on the rear of the Impulse9 which I used to fasten a mount to the OEM rear motor mount assemble. Here are some pictures:
I'm yet to confirm all the specs on these Deka batteries, so, i'm also yet to order them. I do hope to have them for Thursday though. I got the cable to connect them, but don't have the ends, cause i can't verify the size of the terminals. Its all these details that have really made this a long process.
My Curtis 1231C Controller is arriving tomorrow!!! That is very exciting. While i wait for the rest of these details to pan out, i can get busy wiring the rest of the car, and figuring out all the schematics.
The motor went in very, very smooth. Almost too smooth. Its amazing how much space is still in there, aside from the < 1cm between the motor's shaft and the wall! Once the motor was mounted, I was busy making measurement to fabricate the rear motor mount. There are 4 threaded holes on the rear of the Impulse9 which I used to fasten a mount to the OEM rear motor mount assemble. Here are some pictures:
I'm yet to confirm all the specs on these Deka batteries, so, i'm also yet to order them. I do hope to have them for Thursday though. I got the cable to connect them, but don't have the ends, cause i can't verify the size of the terminals. Its all these details that have really made this a long process.
My Curtis 1231C Controller is arriving tomorrow!!! That is very exciting. While i wait for the rest of these details to pan out, i can get busy wiring the rest of the car, and figuring out all the schematics.
Batteries = $$$
Just a quick update: I've pretty much settled on Deka GC12V batteries, and i'll be fitting the battery tray in, tomorrow morning! Sunday, I plan to install the motor and transaxle!
Also, a HUGH thank you to MXenergy for their very kind sponsorship.
If anyone out there knows of ANYONE who would be interested in further sponsoring my electric car, I welcome all support; Barter, services, trade, parts and/or monetary.
Also, a HUGH thank you to MXenergy for their very kind sponsorship.
If anyone out there knows of ANYONE who would be interested in further sponsoring my electric car, I welcome all support; Barter, services, trade, parts and/or monetary.
Batteries found
Hey there! So, I spoke with Daryl from Deka Batteries today, who found me a cross reference for the Trojan t-1275 to a Deka GC12V, which are in stock at the warehouse. I could've had them for tomorrow, but I'm going to make a few measurements this week and get them in for next Thursday!!! Very exciting.
Controller and Adapter ORDERED!!!
Okayalright! So, I've recieved my Impulse 9 motor and it daunts me to put it in everyday. But until i get the rest of the crutial parts, I can't do squat. This has driven me to move forward and make some decisions.
This order:
1 Curtis 1231C
1 EvSolutions Adapter Plate and Coupler
1 Precharge resistor
Now, once these guys arrive, we'll really be in business. And in the mean time, I can begin working on the side and cross motor mount. I'm still looking for some funding to lighten the load on the cost of batteries. Hopefully, by the time that these parts arrive and are being installed, i'll have made some headway there as well.
This order:
1 Curtis 1231C
1 EvSolutions Adapter Plate and Coupler
1 Precharge resistor
Now, once these guys arrive, we'll really be in business. And in the mean time, I can begin working on the side and cross motor mount. I'm still looking for some funding to lighten the load on the cost of batteries. Hopefully, by the time that these parts arrive and are being installed, i'll have made some headway there as well.
Parts Arrived
Quick update, as i've gotten thrown in many directions over the past few weeks. My first round of parts have arrived and all looks well. I'm still looking to solve a few more problems before the project leaps forward, but its all going to happen very soon. And now, there is some serious consensus regarding the Controller. In short, Kelly is crap! Although i am very interested in the features of the Kelly controller, my understanding is that the actual components of the Kelly controllers just aren't up to par. I may just have to digress and use a Curtis...
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.
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.
PARTS ORDERED!!!!
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!
Ordered:
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."
Ordered:
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.
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...
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, fina
lizing 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!
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, fina
lizing 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!
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