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Trev
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Posted: 07 December 2006 at 8:37pm | IP Logged Quote Trev

30/11/06
Hi All,
Finally started the Electric Vehicle (EV) conversion. The plan is now to focus with this to completion, so I will endeaver to keep you all updated on progess.
The vehicle is a 2000 Hilux.

For those of you that don't know, This extension to our business (EV Parts & Conversions) we have been working on for some time. We now have all the necessary bits and just starting the hard stuff now - remove all petrol equipment, design & manufacture the adaptors, battery holders, and fit out all the electrical stuff.

Canopy is off, Ute Body off, measured up for battery box to be fitted under tray, obtained steel and other materials. The battery box has been cut out.

You too can convert your car. Info gleaned from a number of sources, indicates that general cost for electricity is $1 per 100km. Petrol can't compete. And then with solar and wind power - you take a guess????????

Hav'n Fun
Trev

Foundry & Fibreglass
P O Box 55 (326 Proves Road)
Kuttabul Qld 4741
Ph/Fax: 0749540285
Mobile: 0423125400



Edited by Trev on 07 December 2006 at 8:47pm


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Posted: 07 December 2006 at 9:03pm | IP Logged Quote Trev

The vehicle now is stripped as much as posible. Engine, Engine computer control, radiator, exhaust, fuel tank, fuel lines, all clutch parts, air cleaner, bolts & brackets (everything possible) are all out. We have a pile of spares if anyone is interested????

The battery box for the back (under tray) is made from ply and fibreglass coated inside & out. It will hold 10 x 226 A/hr batteries. Just sitting in place for the pic. The steel work is done underneath.



Edited by Trev on 07 December 2006 at 9:05pm


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Posted: 14 December 2006 at 9:48pm | IP Logged Quote Trev

Another busy week.
Started with getting the motor out of the box, measuring everything up, & drawing rough sketches of what had to be made to fit the motor to the gearbox.

The adaptor plate pattern made from ply. Then kick the kids out of my sand pit (Foundry) and get the piece cast in alloy. Machine the adaptor plate on the mill. On to the lathe to machine the shaft connector. The spline is out of the centre of the clutch plate, the machined part is heat shrink onto this spline centre and then TIG welded. There is no clutch needed so it is removed. The motor stops when throttle is released. Gear changes can then happen, but is not generally needed because electric motors have all torque at zero revs and these will rev to 7000 rpm +. Just put in gear & away you go.

Motor was lifted in by hand... just joking...we did it with the chain block and fitted to the bell housing, shaft connected, & fitted perfectly.

Next is to make the engine mounts.















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Posted: 17 December 2006 at 1:02pm | IP Logged Quote Feral

Trev, Can ask what is the dc motor out of and what are it's details, ie, volts , amps, number of poles and weght ?
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Posted: 17 December 2006 at 7:28pm | IP Logged Quote Gizmo

This has got me interrested Trev. Once you've finished the conversion you should let us know how much it would cost.

The other day I was looking at a car that was for sale, it was a 80's Ford Meteor, and I was thinking EV conversion. They wanted $250 for it, pretty cheap and it was almost road worthy. But then I noticed the automatic gear box, and didn't think this would be suitable for EV conversions, too much power lost in the torque converter.

Glenn

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Posted: 17 December 2006 at 8:25pm | IP Logged Quote Pt w/field Matt

hi gizmo you would not be using the t/converter but would have to have a small hydraulic pump for the hydraulic systems in the box,most modern autos take little power to drive these circuits

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Posted: 19 December 2006 at 10:28am | IP Logged Quote Trev

Some info that may answer some of the q's...

Feral, don't know the exact amp draw and its not correct but to get an idea divide the watts by the volts. No idea of the number of poles, these are brand new made by Advanced DC Electric Motors. I am using the FB1-4001 in this Hilux ute.

Glenn, you may do away with the gearbox, reverse can be done by reversing the poles on the motor, and speedo can be worked out by other means. It has been done before. Click on the link, scroll down to find the 'White Zombie'. It has no gearbox.
http://www.nedra.com/
http://www.nedra.com/


Advanced DC Electric Vehicle Motors

A90-4002
Suitable for small vehicle (e.g. golf cart)

Operating range 24 to 36V
Weight: 25kg
Diameter: 17cm (6.7") Length: 24.4cm (9.6")

At 24 volts
Continuous rating: 1.5 kw (2.0 hp)
One-hour rating: 1.65 kw (2.2 hp)
At 36 volts
Continuous rating: 2.25 kw (3.0 hp)
One-hour rating: 2.5 kw (3.3 hp)

AOO--4009
Suitable for small electric vehicle (e.g. golf cart, people mover)

Operating range 36 to 48V
Weight: 25kg
Diameter: 17cm (6.7") Length: 26.4cm (10.39")

At 36 volts
Continuous rating: 3.1 kw (4.15 hp)
One-hour rating: 3.5 kw (4.65 hp)
At 48 volts
Continuous rating: 4.5 kw (6.0 hp)
One-hour rating: 4.8 kw (6.4 hp)

K91-4003
Suitable for on-road electric motorcycle, or micro car. Not more than 750 kg.

Operating range 48 to 96V
Weight: 25kg
Diameter: 17cm (6.7") Length: 29cm (11.5")

At 72 volts
Continuous rating: 6.0 kw (8.0 hp)
Peak output: 16.5 kw (22.0 hp)
At 96 volts
Continuous rating: 7.3 kw (10.0 hp)
Peak output: 21.3 kw (29.0 hp)

X91-4001
Suitable for small to small-medium electric car. Not more than 1250kg.
This motor gives excellent performance at 120V in a car under 1000kg.

Operating range 72 to 144V
Weight: 37kg
Diameter: 17cm (6.7") Length: 39cm (15.3")
At 72 volts
Continuous rating: 7.5 kw (10.0 hp)
Peak output: 24.0 kw (32.0 hp)
At 96 volts
Continuous rating: 9.0 kw (12.0 hp)
Peak output: 39.0 kw (52.0 hp)

L91-4001
Suitable for small to medium-size car. Not more than 1600kg. Better suited to vehicle weight under 1250kg. This motor is physically similar to the x91-4001, but wound to give higher speed. Maximum system voltage for this motor is 120V.

Operating range 72 to 120V
Weight: 37kg
Diameter: 17cm (6.7") Length: 39cm (15.3")
At 72 volts
Continuous rating: 8.7 kw (11.5 hp)
Peak output: 28.5 kw (38.0 hp)
At 96 volts
Continuous rating: 10.3 kw (13.6 hp)
Peak output: 46.5 kw (62.0 hp)
At 120 volts
Continuous rating: 12.0 kw (16.0 hp)
Peak output: 54.0 kw (72.0 hp)

203-06-4001
Great in a small to medium-size car for its superb acceleration and top speed. Will drive a family-sized electric car very well. Not more than 2000kg, but better suited to vehicle weight under 1600kg.

Operating range 72 to 120V
Weight: 48.5kg
Diameter: 20cm (8.0") Length: 37cm (14.7")
At 72 volts
Continuous rating: 12.1 kw (16.0 hp)
Peak output: 31.5 kw (42.0 hp)
At 96 volts
Continuous rating: 14.4 kw (19.0 hp)
Peak output: 51.0 kw (68.0 hp)
At 120 volts
Continuous rating: 16.3 kw (21.7 hp)
Peak output: 62.0 kw (83.0 hp)

FB1-4001
The top of the range. This motor gives stunning acceleration in a car 1200 to 1500kg. Drives a 2000kg vehicle very well. High torque means you get superb pulling power from a standstill or accelerating from low speed. Ideal for sports or racing cars. Has been successfully used in heavy electric vehicles. Generating up to 100 horsepower at 144V, this motor redefines the concept of a car that is "fun to drive"!

Operating range 72 to 144V
Weight: 65kg
Diameter: 23cm (9.1") Length: 39.7cm (15.6")
At 72 Volts
Continuous rating: 12.8 kw (17.0 hp)
Peak output: 31.5 kw (42.0 hp)
At 96 Volts
Continuous rating: 15.0 kw (20.0 hp)
Peak output: 52.5 kw (70.0 hp)
At 120 Volts
Continuous rating: 19.0 kw (25.2 hp)
Peak output: 63.8 kw (85.0 hp)
At 144 Volts
Continuous rating: 21.5 kw (28.5 hp)
Peak output: 75.0 kw (100.0 hp)

Typical application for various motors

Up to 750 kg
K91-4003 Lightweight (e.g. motorcycle)
X91-4003 Low current draw, range-minded
L91-4003 Higher acceleration and performance

750 to 1250 kg     
X91-4001 Very efficient, range orientated
L91-4003 Excellent acceleration and performance
203-06-4001 High performance, good in hilly areas

1250 to 1600 kg     
L91-4003 Commuting with few hills
203-06-4001 Performance oriented, hills & inclines
FB1-4001 Hills, inclines & payloads

1600 to 2000 kg     
203-06-4001 City commuter vehicle
FB1-4001 Heavy loads, area with hills & inclines


Pricing
The following table lists the current pricing within Australia.
Prices - include GST
        - subject to change without notice

A00-4009       $1419
K91-4003       $1595
X91-4001       $2222
L91-4001       $2195
203-06-4001    $3245
FB1-4001       $3949




Edited by Trev on 19 December 2006 at 10:32am


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Posted: 21 December 2006 at 9:49pm | IP Logged Quote Trev

Engine mounts, and battery mounts made, painted and fitted. Steel under the battery box is also painted.

Of course there is always something to annoy along the way....battery rope handles......several batteries are sitting in place, 3 under the bonnet.

1 is for the 12v system, lights, blinkers horn etc. Normally it is not needed to be this big, but I plan to experiment - see if it is possible to run the air conditioner using the 12v system.

The other 2 are to be connected in with the 10 from the battery box in the back, thus making up the 144v system for the drive motor. The battery box is bolted down, with 3 batteries in.

The throttle potentiometer is fitted and cable is connected.

Main contactor is bolted on.

Vacuum pump is sitting where it needs to go.















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Posted: 28 December 2006 at 8:28pm | IP Logged Quote Trev

A lovely week, hope you all had a great Christmas.

Some very exciting happennings this week, mounted the motor speed controller, 12v battery charger & the 144v battery charger. The vacuum pump is mounted. The BIG RED knob(safety push button)is also mounted. All batteries are fitted.

Then to running the cables. Excellent. We have acchieved the 144 volts at the front, with 50mm cable clamped securely underneath from rear battery box to the batteries at the front, in flex conduit. The 50mm cable lengths are cut to connect the BIG RED knob. Still to connect is the Main Contactor, Speed Controller, & Motor.

But of course there is the dash, my intention is to make it look authentic, not just adding higgilty piggy.
There are still some panel meters I wish to put in, but don't have yet. In the pic of the instrument panel you can see the 'fuel guage' for the 144 volt system.

As for disasters this week, none really...... but I hate RATS. Found a nest in the air-con fan.

May you all have an exciting NEW YEAR, ALL YEAR.











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Posted: 03 January 2007 at 10:42am | IP Logged Quote Trev

Had to sort out a few thing on the net, so have looked at the windmill stuff a little also.

The motor is up and running yesterday. 12v charger is now connected. The 144v will be soon. And the Megapulse units.

Need to make the tray and fit the panel meters (I don't have yet).

Can't wait to drive it.......

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Posted: 04 January 2007 at 9:17pm | IP Logged Quote Trev

Got the 144v Zivan battery charger connected and left both this and the 12v charger run to charge up the batteries, while I continued tidying up some minor things.

The vacuum pump for the brakes fitted and connected. It is activated when the brakes are applied. This is the only thing Marcy doesn't like. It sounds like some one doing a big loud fart!!! Some did say once, "skid marks" in that part of the clothing.

The Megapulse (battery desulphator) units are fixed and connected in the front, except one, ordered another batch (any body want one). These in the front are all 12v units. In the back, there will be 2 x 48v Megapulse units and a 24v Megapulse unit. It would have been better if I had all the batteries for the 144v system in the back, then I could have just used 3 x 48v Megapulse units.

The dash it still in pieces, still some wires to trace and reconnect, like the dash fan. It used to go through the engine computer control which is no longer in there.
Other minor things still yet to do also.

The most exciting event was this afternoon we took it out for a spin. First went to see my sister and Marcy's brother (married) (they met at our engagement)(keep it all in the family). About 2 km from here. They too are interested in this electric concept. Spent some time there. When Dale woke from his afternoon nap, Dale and I went for a ride, down the cane paddock. Marcy then had to take it over to the neighbors. It is excellent.

I cleaned up the shed a little while she was gone. When Marcy got back, I continued tracing some wires.

Still don't have the amp and volt panel meters that I want for the dash, but we are getting much closer now, I have found two suppliers, tomorrow I should have some more info. Internet is so much easier to find stuff compared to years gone by, but still can be so frustratingly time consuming.

The main fuse to the speed controller should be here tomorrow too, 500 amp.

Not sure if I have said it before, but I beleive that I will be the first in Australia to be able to do a complete EV package. Motors from one place, speed controllers from another place, batteries from another, chargers from different places, panel meters, fuses, vacuum pump etc are all different places, the list goes on. It has been quite some time to get this all together too. We started considering the concept a bit over a year ago.

And its all very exciting.

Anybody that is interested just give us a call, we will take anybody for a ride & discuss the options available.





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Posted: 11 January 2007 at 9:10pm | IP Logged Quote Trev

Not much done to the EV this week. Wasted too much time building a hole punch machine,(& dismantling, modifying, & reassemble too many times).

In the past I used to have the holes put in at Foxcon Aviation. If you want a good, extremely light F/g plane, these are worth a look. I cast & machine the reduction drive units, front wheel mounting, and the brake parts, for these planes.

The 5mm Klegecell foam is Ok with the drill to wind it through, but the 12mm is just too much. I had to wind it through with a vice grip as a handle. The holes are to add a sthrengthening tie between the layers. Just like the centre of an I beam.

I used the 5mm Klegecell foam for the base on the rear storage box, ( which fits under the tray) and 25mm Polyurethane foam for the sides. The top - the tray itself - will be made from the 12mm Klegecell, all glassed over. It will be very light.

In terms of the electrics, the fuses (500 amp)have arrived. The amp & volt guages have been orderd, but I expect will take some time - hopefully not too long though.









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