DIY Electric Car Forums - Blogs

Making progess, two steps forward, one back

rmacey — Sat, 28 Aug 2010 01:28:18 GMT

Going at it step by step per instructions. Biggest advance has been to install new clutch and fit it to electric motor. The transmission is loosely connected to the motor. I have to figure out the right bolts since the adaptor plate now in place is considerably thicker than the sheet metal on the original car.

I followed a video from the vendor of the kit I'm using to install the clutch. Felt very proud. Then I looked at the written instructions which differed mentioning that the distance between the adapter plate and the pressure plate should be 1.3" +/-.01". Oops. Had to undo and redo.\

Still, it's exciting to see the motor attached to tranny even if loosely.

I keep removing ICE stuff I could have gotten rid of before but wasn't sure what it was. I'm sure there's still more. I either don't know what it is or how I should do it.

Here are links to pics. Comments appreciated.
http://picasaweb.google.com/lh/photo...eat=directlink
http://picasaweb.google.com/lh/photo...eat=directlink
http://picasaweb.google.com/lh/photo...eat=directlink

Back at it

rmacey — Sun, 08 Aug 2010 22:23:07 GMT

No good excuses for why I haven't worked on the car. I can blame the heat and spending my free time at lake. Real reason is that I've been frustrated by next steps. Today, I got back to it. My friend David M. and I set up a "workbench" using a couple of saw horses and pulled the motor out of the box. That alone was kind of motivating. We bolted the adaptor ring to the motor. Then we put on the clutch pressure assembly plate following the instructions from my kit provider. This necessitated the purchase of a torque wrench (must be serious now). Then looking over the VW service manual, I read the cautionary note "Always use new pressure plate mounting bolts...". I used the old one. I will have to find new ones and undo this. Given the torque and the high octane loctite, I expect this to be a bear. Oh well, that's what this project is all about.

Also, found some brackets I had been looking for.

first testdrive!

brainzel — Wed, 21 Jul 2010 09:03:00 GMT

Sunday our New Beetle rolled out of the garage on it's own! We got on a testdrive in our neighborhood, just to feel this great moment :-)
There is still a lot of work to do, but this milestone was a big rock! :-)
So stay tuned ... it will go on :-)

Success!!! The Ban on EV Conversions in Ontario, Canada is Over!!!

eco steve — Fri, 16 Jul 2010 02:04:37 GMT

Thank you From
http://www.10n10.ca/e/Ontario%20EV%20Ban.shtml

2010.06.08

Ontario's Ban on Electric Cars

Success!!! The Ban on EV Conversions is Over!!!

Yesterday (June 7, 2010), Electric Mobility Canada sent out an e-mail advising its Ontario members that MTO has lifted the ban, and has implemented an interim solution for the licensing of electric vehicle conversions. That e-mail read (in part):
"Dear EMC Ontario members, "I am pleased to announce that following consultations with officials at the Ministry of Transportation of Ontario (MTO) I have been advised by MTO this morning that the temporary moratorium on the registration of internal combustion engine vehicles converted to EVs in Ontario has been lifted.
"Effective today, converted vehicles can be registered as EVs at the following 3 locations:
* In Ottawa at the Laurier Avenue licence office
* In Toronto at the College Park licence office
* In Toronto North York at the Yonge and Sheppard vehicle office.
"To register, please bring along the vehicle safety standard certificate provided by an authorized garage.
"At the vehicle licence office, you will need to sign a declaration to the effect that the vehicle has been converted to EV operation.
"Upon registration, MTO will issue a decal for placement on the vehicle. This decal will alert first responders that the vehicle is an EV.
"EMC is appreciative of MTO�s collaboration in this important area.
"Further to the above, EMC has agreed to work with MTO in developing guidelines to define appropriate safety requirements for EV conversions. And, through MTO, EMC will work with the MTO counterparts in other provincial and territorial jurisdictions to achieve national consensus on such guidelines. When this process begins, EMC will involve its interested members."
If the Ottawa or Toronto locations are not convenient to you, I suggest you contact MTO or ServiceOntario directly to see what arrangements can be made to assist you in registering your converted electric vehicle.
Based on this communication, there is no longer any need to protest to the Minister or other government officials about this issue. However, communications to those officials of thanks for attending to the matter in a reasonable fashion will undoubtedly carry shock value (in a good way).
Now, let's get busy and put some more zero-emissions EVs on the road. If you are doing a conversion, you have until June 30, 2010 to qualify for the retail sales tax rebate. (Rumour has it that conversions will not qualify for any incentives under the new rules starting on July 1st with the advent of the HST in Ontario.)

Additional Material from MTO

I have not been able to find a press release from MTO related to this subject.
Their original link at http://www.mto.gov.on.ca/english/dan...ml#conversions (that worked yesterday) seems to have disappeared. The text that was there:
"Electric vehicle (EV) conversions CAN be operated on roads in Ontario. "Ontario is reviewing registration and safety requirements for vehicles that have been converted to electric power. In the interim, the following registration rules apply. Please note that these rules may change in the future.
"EV conversions are:
� Road worthy vehicles that have been converted from an internal combustion engine (gasoline) to an electric power engine.
� Powered exclusively by an electric battery.
� Not equipped or powered by an internal combustion engine or any other method.
"To register an EV conversion in Ontario, you will need the following:
� A completed EV Conversion Declaration form (PDF).
� A valid Safety Standards Certificate (SSC) completed after the conversion date.
� A vehicle permit if the vehicle is already registered in Ontario; or appropriate vehicle registration documents.
� Two EV conversion decals (pictured below) which must be affixed to the front windshield and rear window of the vehicle. The decals will be provided at the Driver and Vehicle Licence Issuing Office.
"An EV conversion may only be registered at the following three Driver and Vehicle Licence Issuing Offices:
� College Park (Toronto) � 777 Bay Street, Toronto, M7A 2J3
� Downtown Ottawa � 110 Laurier Avenue West, Ottawa, K1P 1J1
� North York (Toronto) � 47 Sheppard Avenue East, Toronto, M5W 1G9"
MTO's EV Conversions FAQs (for the new rules as of 2010.06.07)
PDF file of the MTO Electric Vehicle Conversion Declaration form
Image of the Electric Vehicle Conversion decal (JPG)

(The remainder of this page is left in place for historical purposes.) Issue

In early February 2010, the Ontario Ministry of Transportation (MTO) began a secret campaign to refuse new registrations of electric cars in the province. As a result, Ontarians cannot qualify for the only incentive Ontario offers individuals for putting an electric car on the road today - a rebate of the Retail Sales Tax (but only up to $1,000.00). That incentive expires on June 30, 2010, with the introduction of the HST. We have looked for new rules, regulations or written policy to justify recent actions, and have found none.
�I�m sure there were good reasons at one time to prevent electric cars from being on Canadian roads, but we�ve got to find a way to ensure that our regulations don�t become an impediment from doing what�s right for the environment.�
- Ontario Premier Dalton McGuinty - reported June 19, 2007
Electric vehicles have been operating on Ontario roads for more than 100 years, without significant issues in safety, use or licensing.
�ONTARIO PAVES THE WAY FOR ELECTRIC CAR�
- Ontario's Office of the Premier dated January 15, 2009
Despite repeated requests for written policy justifying the unannounced moratorium, none has been produced by MTO officials. Instead, a series of contradictory excuses has been handed out to would be registrants on a a one-by-one basis. Calls to ServiceOntario continue to get the response that there is no reason electric cars cannot be registered in Ontario, based on laws and regulations in effect today.
�Electric vehicles are the way to go in Ontario.�
- Ontario Premier Dalton McGuinty - reported July 15, 2009
Up until the unannounced licensing ban was imposed by MTO, electric vehicles were subject to exactly the same mechanical safety inspections as any other vehicles in Ontario. MTO officials remain unswayed, and have continued refusing registrations of electric vehicles. MTO officials prefer to call the current practice a moratorium. However, a moratorium implies the practice will stop at a defined time in the future. MTO officials are not committed to re-instating registrations for electric vehicle conversions, and certainly not by a defined date. Therefore, the current practice is not a moratorium, but a ban. (This ban does not apply to electric-assist bicycles, as they are not licensed for road use by the provincial government.)
�The McGuinty government's plan is to have one out of every 20 passenger vehicles on Ontario's roads (be) an electric vehicle by 2020. Green licence plates will encourage Ontarians to think green when choosing a vehicle.�
- Ontario Transportation Minister Jim Bradley - reported November 4, 2009
A number of forward-thinking Ontarians, unwilling to wait for the automakers to deliver an electric car for sale after more than 40 years of promises, and thinking Premier McGuinty and MTO would support their initiative based on public statements made by the Premier and Minister, have made their own electric cars. This is an expensive undertaking, and now their personal investments in a better environment are in limbo.
Will the McGuinty government's 'green car' talk end up on the trash heap like their commitment to close all coal-fired generation in the province by 2007? Probably, unless Ontarians speak up and demand that the secret ban on electric cars in Ontario be repealed immediately!

Eco Steve thanks http://www.10n10.ca/e/Ontario%20EV%20Ban.shtml

Picking Your Dream Car for Conversion

eco steve — Wed, 14 Jul 2010 20:53:44 GMT

Picking Your Dream Car for Conversion

So I am converting a 1984 Pontiac Fiero, well you may ask your self why? A Fiero. Well I have always wanted three cars, A Fiero, DeLorean and Lamborghini. So after a deer hit my dino drinker, I decided to tack the plunge. So your almost there, ready to take the plunge as well to convert a car from gas to electric or maybe you dino drinker is on its last legs and is going to need to be replaced soon. Well you can replace one dino drinker with another or plan ahead and take a few months to convert another dino drinker to electric just in time to replace your ailing car. A few things to keep in mind before you take that plunge are simple things like;

If you have always wanted a certain type of car but it was always just out of your reach you can normally find one that has a blown motor or needs a lot of mechanical work in order to get to pass testing for a reasonable price.
A junky gas car will make a junky electric car.
Try to do a gas to electric conversion not restoration unless it�s your dream car.
If money is tight and you have the room you can stretch the conversion out even further and like everything else things (parts and pieces) will come your way, just think positive.
Don�t listen to the dream swishers.
Try to find a Haynes repair manual before you touch a nut or bolt.
You deserve this

So if you are going to finally put your dream in to action,

Wait a minute, Doc. Ah... Are you telling me that you built a time machine... out of a DeLorean?

The way I see it, if you're gonna build a time machine into a car, why not do it with some style?

Make it your style, have fun and prove them all wrong. If you can build Lego and with the tech help and resources of this great DIY forum you can do it! You deserve this.

Here is a link for average used car prices http://www.domesticsale.com/autoclassified/prices.html, so if you can find a good "broken" (motor blown or other) used car for a cheap price, throw in some elbow grease and parts, you just might come out even with the cost of a "good" dino drinking car but without the gas and maint. Most conversion kits go for about $5000.00 - $8000.00.

P.S. Don�t forget to wave at all the non believers at the gas pumps

Eco Steve

Electronics Assist Download resistor colour code calculator,resistance,cap acitance...

eco steve — Wed, 14 Jul 2010 00:49:45 GMT

Hello All,

Found a great little download that has a bunch of great electronic tools. Electronics Assistant is a Windows program that performs electronics-related calculations. It includes a resistor colour code calculator, resistance, capacitance and power calculations and more. Details of calculations can be saved or printed. It provides all the functions found in the calculators section of this site and more in a stand-alone user friendly program.

http://www.electronics2000.co.uk/download.php#assistant

I found it very helpfull and easy to use and the fact that you can print your data is great when you are scratching your head in the garage.

Scanned for Viruses all OK. Please offer feedback for all.

Eco Steve

You Can't Do That!!! (the day the dreamers "grow up")

eco steve — Fri, 02 Jul 2010 02:48:43 GMT

Changing our world one kilometer (or mile) at a time.

After people tell me, "You can't do that for next to no money, made from a recycled
car, recycled batteries, recycled wires and recycled dreams."

It kind makes it hard to just let it go, knowing how easy this converting process is. A couple weeks ago deer hit me on the way to work and destroyed our car, we were going to replace the car with another "beater" as a commuter car but thought this would be a perfect time to realize our dream and convert a car from gas to electric. We started looking more intently for a car which would make a ideal donor car and found Brian.

Below is a picture and video of Brian Sauve the person who donated our first donor car, Brian dream originally was to convert this same car to electric but time does run away. Here he had just drove the car onto the car trailer for us (Uhaul rocks). It was a sad moment for Brian but he was very happy that his car will have the second life in the manner he dreamed of. When this conversion is operational Brian will one of the first and few to drive this reincarnated "Lean Mean Clean machine"[/left]

The car now in our drive way after searching for this model for over a year and a half now safely in our drive way. The planning and time lines start, six weeks the goal to have the car "operational" may be harder to adhere to as working on the car out side with no garage dancing with mother nature (she always wants to lead). The full range target to work and back is 150 kilometers (93.21 miles), down hill to work and uphill back its like a 12 hour roller coaster, 12 hour slow roller coaster.
Plugging in at work would not only reduce my need for full range from 150 km (93.21 miles) to 100 km (62.14 miles) it would also lighten the vehicle thus placing less stress on bearing, joints, suspension and other mechanical items.

Lightening the car would also allow it to maintain what little cargo space is has and allow "a passenger" other that bobble heads.
Adding solar panels on the roof unfortunately will not add much generating capacity (except maybe to charge the 12 volt operating system. You need a lot of amps to charge batteries and a couple of 100 watt solar panels only generate about 16 amps, I think the car would have to be parked in the sun for about 3 days straight to charge the batteries up to full, but I still learning this whole amps, volt and watts language. But I think a couple of peel and stick solar panels as racing strips up the hood, across the roof and down the tails might be a nice touch.

It does make the mind, body and spirit work harder, to improve and prove that dreamers are the ones most planted firmly, success is in my dreams and reality. Only you have the right to deflate your dreams.

Being a Pro Eco Recycler

eco steve — Sun, 27 Jun 2010 05:29:41 GMT

Here are a few strict guide lines that I follow to ensure a happy and productive partnership of parts. Remember most companies have to pay to get rid of some surplus.

1.If you don't ask you will not receive legally, I have received free things like:

-73 used power packs (retail $200 ea. total $14,600)
-1 3000 watt 12 volt inverter with 1 blown internal fuse
-1 1750 watt inverter
-20 Deka Ungly 45 ah deep cycle batteries (retail $3000)
-Free sheets of 4 x 4 cedar plywood (?)
-3 wood stoves
-Clay to make a earthen oven
-3 72 volt forklift motors (retail $1200)
-600 amp Zappi 72 volt forklift controller with regen. braaking (retail $3000)
-Large satellite dish to make into a parabolic solar cooker
-43 used light fixtures to make into solar hot air collectors (Instructable)
-15 100 ah 8D AC Delco RV batteries (retail $4500)
-17 Square D 761 safety disconnects
-5 15 watt 12 volt solar panels
-1 100 watt 12 volt sharp solar panel
-36 feet 4/0 forklift battery cable
-Glass for our greenhouse
-3 water heater
-300 feet of fibreglass cloth
-3 toast ovens
-coolers of free vegetables to feed our vermicompost pile
-paint, fibreglass resin, pool chlorine ..........
-pond pump
-$2000 free lumber
-swimming pool
-2 camper trailers
-boat
-2000 feet of mixed color copper wire

And the list goes on and on and on

Ask if there is something that they need, try trading items

BUT DON'T STEAL!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

2.Tell them what you are really doing, don't lie, they will be even more happy to help you if they really dig your project. Be excited and let them live through your project . When I told people at work that I was building a electric car I received 20 Deka Unigy 45 ah deep cycle batteries (retail $3000) for free as they were swapping out old ups batteries from a back up system.

3.If they say no because they need it, don't steal, ask if they may know where you may get one.

4.Offer to pick up the part(s) at their convenience night or day and if you are qualified, offer to remove the parts with your own tools and ask what tools you will need when and if you need to come back (mechanics are very sensitive of their tools).

5.If they scrap parts for scrap metal weight or trade them in for a core charge, offer to pay them in cash for that.

6.If you have special skills that they may use, you can also barter your services for their parts.

7.Don't sell the parts for any reason, if the donor company finds out they will cut you off.

8.Clean up after yourself.

9.Don't be a pain in the rump, ask when to call again or if they want to call you.

10.Don't hog things' spread the wealth give things away too, ask if they need it back if you can't use it after all.

11.Don't sort or separate there take it all home, don't be a pest and most important - clean up after yourself.

12.Do be very thankful.

13.Do be educational.

14.Do be humble.

15.Do bring 1 or 2 pictures of you project so they may see your vision and also become inspired.

16.Have fun and wear safety shoes and always have a first aid kits.

Eco Steve

done with phase two

lou-ace — Wed, 16 Jun 2010 05:24:58 GMT

I know that I�m killing everyone with minute, but I�m very proud of the work that I�ve done so far. The motor and transmission is now mounted in the truck, motor mounts have been fabricated, placed and are rock solid. Tomorrow I will raise the drive wheels and give her a good testing of the drive train. This will conclude what I term phase 2, the mechanical refit of the EV. Next will be the design and implementation of the electronics�. I�m heavily looking toward my counselors at DIY t help me here as I am quite mathematically and electronically challenged. I do well with the heavy work, soldering, and wiring, but I don�t pretend at all to understand the principles of what I�m doing. The mathematics required to understand the amperage (total) to match the components i.e. contactor specs. And wiring gauges still feel like mysteries to me but hopefully all works well. What I�ve learned is that I think I will choose a higher rated controller (either the Kelly 144v/800 amp- or the ubiquitous Curtis 1231c 500 amp) and hopefully not be disappointed. I�m still planning on using # 12 gp 27 deep cycle batts as my power pack I hope that gets me at least 40 mi. range. As I have a charging station at work.

Attached Thumbnails

finally connected

lou-ace — Thu, 10 Jun 2010 04:46:47 GMT

Finally, after cajoling the machinist for a month, I finally got my connector between the motor and trans. I do have to hand it to Jon at Portland Manufacturing, he did a great job fabricating this connector it fit like a glove, and after assembling the motor and trans. It ran like a dream. The bench test was 100% successful, I could discern no grinding bearing noises, or binding in the coupling. Now I�m ready to install it in electric red this weekend that should conclude phase 2 ( the mechanical refit) and I should be able to blaze through the electrical, and battery phase. Patience is everything.

Attached Thumbnails

finished up plate-mounted

lou-ace — Sun, 09 May 2010 05:27:38 GMT

Finished up the mounting plate today, cut down the shaft with a 4"cuttoff grinder and premounted the motor and tranny on the bench. It looks like a god fit! And my concentricity looks great. I have the 2" connector being machined in the shop, 1-1/8th keyed on the motor side and I poped the spline out of the clutch and the machinist will lathe it and press it into the tranny side. This will be a direct drive unit. hopefully will be able to do a bench test run within the week. cost so far $ 80 for plate and $60 dollars for machine work. the best hint i recieved so far was in marking the concentricity on the plate. After I had the plate cut and mounted on the tranny I simple took a rubber mallet and swiftly struck the outside of the plate towards the tranny to make a perfect imprint of where the shaft lies ( my plate is 3/8" aluminum I don't konw if I would do that with steel) frome there I used my best measuring skills ( and a good micrometer) to measure my motor mounts. The motor fit like a dream. hope the next phase is as god as this one.

Attached Thumbnails

Why electric?

brainzel — Wed, 05 May 2010 12:33:43 GMT

The reason to get an electric vehicle is surely different to everybody who get flashed by the conversion virus.
Our biggest personal reason is our first electric car, a swiss Solec Riva Junior.

Solec Riva Junior
year of manufacture: 1990 (Switzerland)
Motor: DC 6kW / 8,16PS / 8.046 hp
direct shaft, no transmission, no gears
60 volts out of 10x 6V LeadAcid (Banner 180 Ah)
Vmax: 90 km/h / 55mph
Gewicht: ~ 850 kg / 1870 lbs
range: ~75 km / 46 miles
12" Zoll wheels

New Beetle - translation and aggregation

brainzel — Wed, 05 May 2010 11:48:34 GMT

Hi,

I will try to translate the important points to my New Beetle conversion in this blog. I got some questions about it, because my "original" blog is written in german language.
My english is surly not the best, so please feel free to correct me, ask me questions, comment and be patient to me :)

Michael

back to work

lou-ace — Wed, 05 May 2010 02:14:08 GMT

Ok, Im getting excited now my AMD FB 4001 double shaft motor is coming tomarro. I have the tranny in the shop, replaced seals, fabricated plate and cut tranny shaft to make room for EM shaft, they will be a kissing 1/8" apart. THe hardest part to co-ordinate to this point has been to find a machinist to make the connector. My rig is going to be direct connection from the EM to tranny, no clutch, or flywheeel needed. I purchesed a 1-1/2" piece of stock steel 1/4" wall, the inside is 1-1/16". I found a machinist that will fabricate one end to 1.130 with 1/4" keyway to fit EM, and the other end will have the spline that I punched out of the clutch plate pressed into that end for a neet 2" connector. Im hoping for a mount the motor to the plate, attach the connector to shaft, mount the plate to the tranny and off I go to replace the unit put togeather into the truck, attackh driveline and this will finish what I have termed " phase 2 ( mechanical reconfiguring the EV). I will update again when done with phase 2 with trials and tribulations, before I begin phase 3 ( designing, installing electronics) see ya soon....... Lou-ace

Changes as I go

hargadale — Wed, 21 Apr 2010 03:49:33 GMT

I Made a template of masonite of the transmission bolt patern to transfer onto the .50 inch aluminum plate as the first step of connecting the transmission to the electric motor. My plan was to connect the two Clark forklift motors together end wise. There just enough room to do it in the car. SO.... I went looking for a more suitable motor. I found and bought a Caterpiller electric fork lift truck, the end result was that for $600 I got three 48 volt dc mortors, and a controller. Plus a couple of hydraulic pumps. I also got the sppeed control pot hooked to a pedal. The whole thing was engineered my the engineers at Caterpiller to work together, so I don't have to do that.