[david85]

I have finally started the real part of the conversion.

The engine and transmission are out, and I did some minor measurements under the hood to see how the 200Ah lithium cells would fit. Still have to pull the fuel tank, lines and exhaust system. A cold snap is on the way, so the warm weather is over. Shop is not heated.....

The amount of room behind the front bumper is very encouraging. I figure I can fit at least 24 of the cells under the hood. I will know more once the motor and drive are installed, but at the very least I already have room for 24 of the 48 cells. There is also lots of space behind the bumper corners, not sure what I can install there...maybe the vacuum pump and a few inches of sound insulation on top.

The aluminum sheet metal for the battery boxes is on its way. Sorry, no updates on the brushless motor yet. But I am considering a warP 9" if that proves to be too hard to get in a timely manner. I could always upgrade later and sell the brushed system.

The battery shown here is my sample and the cells are the same model as what the 144V battery will use. There is room for a string of 12 cells right where the radiator used to be, and another 12 cell string against the firewall. The rest should fit below the trunk floor in a custom drop box, so cargo room will be the same after the conversion. In theory, there is also more room at the fuel tank location, but considering how hard it is to get to, I might just leave that empty for now since I already have all the room I need. The only catch is I won't have a place for the spare tire anymore, but it may even fit under the hood. Will have to see.

[rctous]

very cool I didn't know you were doing lithiums,, wished i had them in my budget but NO WAY,, if you are considering the Warp 9 be sure to look closely at the length of the motor they are pretty long, I have the Warp 9 impulse which is shorter,, I will show you pics of it in the bay and then you will know for sure about the length. I was surprised at how close it was in the Storm, a Warp 9 never would have fit. You know I will be following this!!

Brian

[david85]

I concluded that there was 20" of space from the transmission mating face to the structural beam on the opposite side of the engine bay. The engine block is 18" if I remember right. Isn't the warP 16" and change? What sort of space did you find in your car?

Yep I'm using a 200Ah 144V LiFePO4 battery direct from mainland china. I'm aiming for 100 miles of real world range, but with a brushless motor, more is likely (less loss, and regen). The battery is rated at 1C constant and 5C peak rated, so it should perform well. Not quite a tesla roadster, but might out run a stock saturn even with the humble warP.

[rctous]

Originally Posted by david85

I concluded that there was 20" of space from the transmission mating face to the structural beam on the opposite side of the engine bay. The engine block is 18" if I remember right. Isn't the warP 16" and change? What sort of space did you find in your car?.

never took any measurements on the Saturn I know I have plenty of room for the Impulse motor.

[rctous]

looks like the old engine from the back of the block to the very front bolt on the pulley is about 19 inches,, also mt motor adaptor is 1- 1/2" thick as well so that needs to be factored in. It looks like the Warp 9 is about 3 " longer than the Impulse,, that would not have fit in the storm but I should have this one mounted by Thursday and we can look at the pics to see if the room is there.

[david85]

Work on the rear battery box has started. The hole in the floor is cut, and I hope to start work on the actual aluminum battery box tomorrow. My Dad is nearly finished with a metal break he made for the shop press, and I just wrapped up the cad drawing this evening.

The rear beam for the suspension is in the way, so I will not be able to fit 26 cells directly under the trunk, but I can use the space left by the fuel tank to make up for that. This would make for a nice low center of gravity as well as preserving all the interior space. There might be room for the charger in the space over the rear beam but I will have to see once that arrives.

The wood blocks seen under the car are mock ups for the battery cells.

[Vaughninms]

Behind the front bumper? Corners of the bumper? You are putting batteries here? Are you absolutely positive you won't be involved in a crash? Even if you are sitting still, someone could back into you, right? You might want to consider this before committing to an unsafe location.

[electromet]

I'm sorry, but I don't see anything that's a safety hazard here. Everything is well back from the 5 mph impact bumpers and the crossmember they're attached to.

Mike

[david85]

Welcome to the forum

Not behind the plastic bumper skin. And no, not behind the bumper corners either where there is nothing but the plastic for protection. I did breifly think about that, but I agree that would be unsafe, not to mention a pain in the neck to even fit.

It is behind the main frontal support of the car. Behind the structural bumper is where the front box is located. You can take a shot gun to these batteries and they might smoke a little but not much else. Its not the same kind as the dell computer fiasco and they have no significant amount of liquid to spill if they are ruptured.

In fact, I think the locations and tight clearances are very safe because the structure of the car wraps around every battery box so nothing can tear loose. The batteries and the space frame of the car complement each other.

[david85]

And on that note, here is the final box nearly complete and in position

All thats left now is to build the brackets to hold it in place and knock some holes in the side for the wires. Wires have already been routed under the car to the rear main box as well. We won't talk about the BMS wiring harness yet......not looking forward to that.

Oh and there will be about 1/4" of clearance between the box and the controller. Yes, its tight but it fits