wtmusic's electric car hits the road for Earth Day

[wtmusic]

Well it's been 15 months and $15K but I finally have me an electric car. My conversion project has tested my patience and my mechanical skill but I am very, very happy with the results.



This past Sunday I performed the last of three "smoke tests" -- hooked up some wires and smelled for smoke (fortunately there wasn't any). I got into the car, still on jacks, stepped on the accelerator, and more good news -- the wheels turned 'round. Then I bolted the hood back on and the seats back in, lowered the car to the ground and as expected, it sits very low. I estimate it weighs around 2,500 lbs, or 500 lbs short of the gross vehicle weight rating. So it still needs suspension work done, probably stiffer springs and struts.

The car is registered with a temporary registration until it can be inspected to confirm it's an EV (otherwise it needs a smog cert here in CA), so I took it for a very ginger test drive and discovered there is plenty of oomph. Yesterday I got up to 45mph in 3rd gear with lots left over. Today I'm taking it to my son's middle school for an Earth Day demonstration, alongside a GM Equinox fuel cell vehicle...should be interesting. :evilgrin:

I have many people to thank -- Bob Batson at Electric Vehicles of America with his expert guidance, my family for their patience and help, and last but not least my friends here at DU who have offered encouragement and advice along the way.

Past threads:
http://www.democraticunderground.com/discuss/duboard.php?az=show_topic&forum=115&topic_id=80356
http://www.democraticunderground.com/discuss/duboard.php?az=view_all&address=115x87832
http://www.democraticunderground.com/discuss/duboard.php?az=view_all&address=115x94197
http://www.democraticunderground.com/discuss/duboard.php?az=view_all&address=115x133136

Specs

Original car: 1997 Ford Aspire
Top speed (est): 70 mph
Range (est): 45 mi.
Seats: 2
Battery pack: 14 8V Trojan T-875 wet lead-acid batteries for a total of 112V and 882 lbs, 4 under hood and 10 in rear battery box.
Motor: Advanced D.C. FB1-4001
Controller: Curtis 1231C
Transmission: Clutchless manual
Safety: interior batteries mounted in a welded steel and polyethylene box with exterior ventilation; safety harnesses and airbags from original car.

Under hood



Rear battery box (where back seat was)



Instrumentation (traction pack voltage, ammeter, and accessory voltage) under stereo in console

[ixion]

1. congrats, wtmusic!

that's a truly awesome accomplishment. You're going to be loving life when gas hits $6 per gallon. :woohoo: :applause: :woohoo:

[intheflow]

2. Very, very cool, wtmusic!

What a wonderful way to celebrate earthday! We people living east of you salute you for improving our air quality. :patriot:

K&R

[hunter]

3. Wow. Happy Earth Day!!!

:applause:

[kestrel91316]

4. You did that yourself??? I am WAAAAYYYY impressed.

[GliderGuider]

5. Well done!

Congratulations on your project, that's real leadership by example.
Enjoy humming around on Earth Day!
:yourock:

[phantom power]

6. Groovy! K+R

[madrchsod]

7. congrats!!!

you tube videos in the future?

[IDemo]

8. Very nicely done. Now you can begin on mine.

:yourock:

[diane in sf]

9. Congratulations!!! Enjoy your "new" car and your non-existing gas bills!

[Summer93]

10. Excellent!

I like it!

[Canuckistanian]

11. Congratulations!

I hadn't heard any news about the car lately and I was going to ask you.

Happy motoring!

[pacalo]

12. You have no idea how impressed I am.

I consider anyone with auto mechanical skills as impressive, but the fact that you converted one into an electric car is just...WOW...amazing.

[madokie]

13. Congradulations on a good job well done

[kristopher]

14. I'm curious, did you price other types of batteries? nt

[wtmusic]

15. Yes

If you mean other chemistries, I checked into lithium. Valence's LiFePO4 cells are the only ones I would consider putting in a car because of the possibility of a "runaway thermal event" (1000° fire) with other lithium chemistries. Bottom line, for me, is they are too expensive. They cost 6x as much as lead-acid, and although I found similar cheaper ones in China there were bad reports on reliability.

NiMH would be cheap and wonderful if Chevron hadn't deliberately tied them up with patent encumbrances.

So I'm stuck with my bigass golf cart batteries which are working just fine. I rode 27 miles today and have more than 1/2 charge left, which means I've underestimated my range by 10-15 miles.

[kristopher]

16. I think it's cool as hell.

:toast:

[Nihil]

17. K & R ...

... and a big *C*o*n*g*r*a*t*u*l*a*t*i*o*n*s*!

Well done!
:toast: