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Jaguar XK8 (96') EV

51K views 74 replies 16 participants last post by  itchyback 
#1 · (Edited)
1996 Jaguar XK8 Ev (Planning Stage)

hello I'm new to this forum!
I'm planning to start my first EV conversion! And I would like to get as much advice or feedback from this forum so please do leave anything that may help me!

Experience:
I have experience of building 5 E-bikes in past. I had enough with having have to worry about the weather all the time and making sure no one can steal my ebike!
I have working understanding of ICE and MT (not much on AT). I need to do more readings on ECU, gear ratio and other car mechanics...But I'm not afraid of getting my hands dirty!
I have computer science degree and now working as a engineer at auto parts company (working on self-driving EV car).


What I got:
Donor car - 1996-1998 Jaguar XK8 (4.0L AJ26-V8)
0-100km/h - 7.8sec was original
Drag - 0.35Cd
Weight - 3560lbs (1615kg)
-- 1st 3.57:1
-- 2nd 2.20:1
-- 3rd 1.51:1
-- 4th 1.00:1
-- 5th 0.80:1
-- R 4.10:1
-- Final 3.06:1


What I want:
Top speed - 160km/h (100mph)
highway continuous speed - 110km/h (68mph)
Range - 110-150km (70-93mile)
Cost - 20,000USD(exclude donor)

Needs (Correct me if im wrong):
Motor - Kostov K11 alpha
Controller op1 - Soliton 1
Controller op2 - Soliton Jr.
Battery op1- CA100FI(80s)/CA60FI(70s2p)/CA180FI(60s)
Charger - not sure yet
BMS - not sure I'll need it

I've made quick excel to check as much as possible.

So here is where I am at:
got a dealer who can sell me the car for a good price(I'm getting it by April)
started emailing EV parts companies for their shipping quotes (Chinese new year isn't helping me much tho,,,)
looking for a garage I can work and getting to know my local garage shop people.
 

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#67 ·
better not wide enough than too wide, at least you can make the hole bigger :D

I like your slide mechanism, i hope it is strong enough!?

The u-nut looks something like what we call in Australia a Nyloc Nut, it has a nylon ring in the nut that makes it more difficult to undo and less likely to become loose due to vibration.

Keep the updates coming, all progress is good :)
 
#68 ·
The rail I'm using is from this site
It is rated to withstand up to 260kg/ pair.
I am using it for 24batteries per box (80kg each with the frame) so should be more than enough.

I am aware of the nylon nut but according to my research, U-nut is better of two. (and is reusable for many times).
 
#69 ·
update!
This weekend I've completed rear side of rail and aluminium bar attachments. Slight miscalculation...I've got couple holes on the centre bracket misaligned so will need to re-make that part this week. but apart from that, I've managed to assemble all the parts(for test) and they are looking good!
Hopefully by the end of this week, I'll be done with rear battery box!
Impact wrench Impact driver Handheld power drill Tool Hammer drill

up to 16mm capable hand-drill. monster!

Machine tool Metal

Had to weld one of the hole shut

Auto part Machine Machine tool

Angle being painted and bolted.
Machine Engine Vehicle Auto part


Automotive exterior Machine

rail working as it should! (has not been bolted on the car yet)

Next up:
- making the car side of the rail fixture.
 ・Drill holes on car for aluminium bar bolting
 ・complete front end of rail fixture
- rear passenger battery box to be made
- Front ICE(motor) compartment area design
 
#70 ·
I'm still working on the rear battery boxes but and they are coming along nicely.
In the last couple weeks, I've finished fabricating most of the rear battery box rail system.
its been very difficult to work in such a tiny space but managed to get most of it done. (The welding is not the greatest...)
This week, I'll finish painting them and finally test fit batteries in them.
(hopefully it wont fail on me...)

Automotive exterior Bumper Auto part Automotive window part Glass

rear box front support
Automotive exterior Auto part Metal Steel Automotive window part

M6 Nut rivet to secure the front end
Varanidae Iguanidae Lizard Monitor lizard Iguana

rear box rear side support

rear box rear side support
Automotive exterior Machine

Test fitting
Floor Flooring Automotive wheel system Automotive tire Auto part

welded rear box side support
Floor

welded rear box side support

Before I welded the area, I've applied JB weld to make sure fitting wont move and to have little more support in case my weld doesn't go well...
I'll apply JB weld over the whole welded area to make it look pretty and easy to paint.

Next up:
- paint few areas for the rear battery box supports
+ test fit the batteries and a lid
- rear passenger battery box to be made (Mid box?)
- Front ICE(motor) compartment area design
 
#71 ·
WOW its really been half a year?!
Here are some update...but looking back at it, I feel I haven't done anything in the past 6 months!

・I've completed the rear fuel tank battery boxs. They slides in and out nicely and do lock in position very well. (I am planning to build another structure to keep it in place in case of frontal collision or something)
Trunk


・I have completed the rear passenger area battery box(structure) which were quite difficult task as there are plenty of curves on the body. :p

Transport Metal Steel Composite material

Machine

・The 12cells are secured with original seat belt bolts and couple M6 Stainless rivet nuts.
Gas Metal



Next up:
・Front frame and battery boxes(36cells to go!) → hopefully I'll have something to show by April
・High Voltage wiring + 12v system to be made...
 
#74 ·
UPDATE!
Hard to believe couple months went by so quickly!
Since the last update, I've managed to design the engine compartment's battery box.
The photo only shows the base of the box pre-fitted to the car.
I'm currently welding it into a box. (similar to the rear battery box)

Unfortunately, I'll be away for a couple weeks from now so next update will possibly be in a month time.

Auto part Machine Automotive exterior Engine Vehicle

Auto part Vehicle Car Engine Rim
 
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