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  #1  
Old 05-03-2012, 09:59 PM
albo2 albo2 is offline
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Default Finally starting my MX5(Miata) conversion

Decided to start posting progress on my conversion of a Mazda MX5 as I have just got off the phone with my shipping agent and the batteries I paid for in Nov last year are ready to be picked up Monday, I'm sooo relieved there were times I thought I had blown 7000 bucks, anyway enough of that, I have 32 x 200 amp hour Sinopoly cells this will be my commute car I need a range of 84 kms mostly flat motorway driving, I have purchased an AC50 HPEV motor and controller and various other parts from Randy at Canada EV he's a most helpful guy so all that's really left is a charger and cables, battery boxes and put it all together, before I could start all this I had to build a place to work on the car,

Funny start to saving the planet had to cut down a tree this is a shot of the stump I had to dig out of the ground

Next picture is the finished carport and the engine nearly out after a full day's work the day before with Nick Smith who supplied the brains and most of the brawn.
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File Type: jpg before carport.jpg (67.7 KB, 65 views)
File Type: jpg removing motor.jpg (54.7 KB, 83 views)

Last edited by albo2; 05-04-2012 at 08:42 PM. Reason: forgot to mention all the help I got from Nick Smith
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  #2  
Old 05-03-2012, 10:23 PM
albo2 albo2 is offline
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Default Re: Finally starting my MX5(Miata) conversion

Then I need a shed to quote Jack Rickard "to get liquored up and play with high voltage in"

A photo of the pile of rubbish I started with and the finished shed
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File Type: jpg shed rubbish.jpg (100.1 KB, 42 views)
File Type: jpg shed finished.jpg (92.8 KB, 45 views)
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  #3  
Old 05-03-2012, 10:41 PM
albo2 albo2 is offline
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Default Re: Finally starting my MX5(Miata) conversion

Went to Auckland welding school and fabricated an engine mount quite happy with the result, I hand bent the ring with a bending machine and it's pretty much a perfect circle not an easy thing to make, I knew nothing about welding so although I probably could have purchased the mount cheaper I learned a great deal in the process and ended up with this, retaining the original engine mounts.

Matt and Rock were really helpful I took over a complete day of their time so the price really was quite reasonable.

I would like to put some form of rubber around the motor bracket any suggestions?
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File Type: jpg engine mount on bench.jpg (96.3 KB, 69 views)
File Type: jpg mount in car.jpg (94.7 KB, 74 views)
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Old 05-04-2012, 08:38 PM
albo2 albo2 is offline
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Default Re: Finally starting my MX5(Miata) conversion

Just had a thought well 2 actually

1. Using innertube rubber
2. Putting silicon on the engine bracket and lightly clamping it to the motor covered in plastic.

Please let me know what you think
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  #5  
Old 05-04-2012, 11:11 PM
Salty9 Salty9 is offline
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Default Re: Finally starting my MX5(Miata) conversion

It looks good. I don't think you need anything between the motor and your mounting band. It would slow heat transfer from your motor.
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Old 05-05-2012, 02:14 AM
drgrieve drgrieve is offline
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Default Re: Finally starting my MX5(Miata) conversion

You might want to confirm but I think you can run your controller/motor setup with 36 cells.

So when building the boxes maybe leave some room in case you want to add some more down the track.

Cheers.
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Old 05-05-2012, 05:39 AM
albo2 albo2 is offline
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Default Re: Finally starting my MX5(Miata) conversion

Yes Im still pondering I might try 22 A123 cells in 2 lots of 11 cells each to supply any high current demands and prevent sag 32 cells should give me the range I want without taxing the controller
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Old 05-07-2012, 02:54 AM
albo2 albo2 is offline
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Default Re: Finally starting my MX5(Miata) conversion

Picked up some unobtainium today, 200 amp hour black Sinopoly cells, yes they exist
Attached Images
File Type: jpg batterycrate.jpg (94.2 KB, 78 views)
File Type: jpg batteryH.jpg (93.6 KB, 80 views)
File Type: jpg batteryW.jpg (91.8 KB, 73 views)
File Type: jpg batterydepth.jpg (94.8 KB, 80 views)
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Old 05-10-2012, 03:21 AM
albo2 albo2 is offline
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Default Re: Finally starting my MX5(Miata) conversion

Got the motor sitting in the engine bay today, was going to hire an engine hoist but saw these winches for 20 bucks at the hardware store when I was getting my paint, was a delicate operation, I wrapped the rope around my towbar to raise and lower the engine, worked like a charm, while I was working on it my Cellpro powerlab8 arrived in the mail, will be able to do some testing and confirm how much capacity these cells actually have, will also come in handy for doing what it's really for, fast charging my Helicopter batteries.
Attached Images
File Type: jpg winchSAM_0105.jpg (98.6 KB, 70 views)
File Type: jpg sittingniceSAM_0111.jpg (96.8 KB, 90 views)
File Type: jpg Powerlab8SAM_0107.jpg (94.2 KB, 64 views)
File Type: jpg HeliSAM_0109.jpg (97.8 KB, 64 views)
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  #10  
Old 05-10-2012, 04:08 AM
MN Driver MN Driver is offline
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Default Re: Finally starting my MX5(Miata) conversion

Good to see you with the Sinopoly 200Ah cells. Seems the measurements line up reasonably well, although its hard to tell with too much accuracy when the tape isn't square with the cell, I hope you don't cut wood like that. They are the compact 200Ah cells we've all wanted to see though, so that's great! Nice car.
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