Alright, I’ve decided to make a re-build thread for my new (to me) 1995 Saturn SL2 EV.
I’ve been thinking about an EV for a while, and did quite a bit of preliminary research over the last few months. My requirements are modest. 50 mile range, 5 seats (only kids in the back, so weight/space is not really an issue, just need 5 seat belts), sporty-ish (0-60 in the 9 second range with decent handling), able to cruise at 65 for 10-15 miles, and be easy for anyone to drive. No tricks, no funky shifting, no heaterless/air conditioning less cars allowed here. I settled on the idea of a basic 4 door compact car with a DC motor and lithium batteries, which I figured would fit the bill pretty well. Hopefully something new enough to have air bags and shoulder belts in the rear seats, but not so new that it’s completely computer controlled.
Right about that time, I saw this post
here in the classified forum. Hmm, a free roller, that could be a nice way to get started!
I have always liked the first gen Saturns, and I can’t weld so there’s definitely an advantage to buying something that already has battery boxes and motor mounts made. I emailed back and forth a bit with the owner, one thing led to another and I ended up buying it from him as is. Broken motor mounts, damaged Warp9, all electrics, 48x 130ah CALB cells and all!
Definitely a ‘fixer’ rather than a conversion at this point, but it still needs plenty of work. In addition to the obvious fixes needed to repair the damage, it also has no air conditioning (which I figure I have until next summer to figure out a solution), a non-functioning (but still installed, so hopefully fixable) clutch, a Logisystems 750a controller (one of the few still working from what I can tell, but I don’t hold high hopes for it in the long run) and it needs to have another motor mount added to prevent excess rotation of the motor. In addition to whatever else I find as I tear into the car…
I set up a transport to get the car from there to here (not cheap to ship a non running car!!), and in the meantime while I was waiting I came across this thread
and now have a used Warp9 in my garage waiting to be installed.
While I was waiting for the car, I also procured a big, ugly, rusted engine hoist from Craigslist, bought a hand powered winch to get the roller up the driveway (which required drilling into my concrete floor and installing a half inch wedge anchor), and proceeded to clean out a space in my garage to work on the project.
More in a bit…