I have been reading a lot about electric car for the past year, and I have learned a lot with this forum, I would like to thank you for all the great information that is already written here!
I live near Montréal, Québec, Canada, where the climate is normally cold and snowy, but I will not drive my electric car on winter.
I am studying mechanical engineering, and I have been working on car and mechanic as a hobby for a few years now. I have restored a 1992 Honda Prelude and build a home made CNC router.
I feel ready for converting the 1985 Mazda RX-7 I recently bought for this purpose!
I planned to do this project mainly for energy efficiency, durability, to reduce my ecological footprint and for personal accomplishment. I want an EV that is small, light weight, good handling and relatively powerful. I'm hoping to exceed the performances of the original 100hp Wankel engine!
My budget is around 20 000$, I plan to do complete this project within one or two years, I want to do things right and learn a lot!
Here is what I planned, for now (September 2nd, 2012):
- Warp 11 Motor
- Evnetics Soliton 1 controller
- GM Powerglide transmission (2 speed automatic with manual valve body)
- 3.2 Volt 100Ah LiFePo4 battery (80s1p) or 3.3 Volt 20Ah A123 LiFePo4 pouch cell (90s5p)
The GM powerglide will be converted to run without a torque converter and to shift manually. The bellhousing will be cut to shorten the assembly.
Something like those will be done:
My calculations tell me I should be able to do 110 km (68 miles) with 80s1p of the 100 Ah cell and 120 km (75 miles) with 90s5p of the A123 cells using 300 Wh/Mile.
Constant speed drag calculation give me bout 230 Wh/Mile at 100 km/h (62 Mph).
I used an Excel spreadsheet I have created, I considered air drag, tire rolling resistance, 1000 W of accessories, 80% DOD and a "battery to wheel" efficiency of 74% (94% controller, 88% motor, 90% transmission).
The car weight 1085 Kg according to the registrations and the GVWR is 1305 Kg.
377 kg have been removed yet.
-Engine and auto trans assembly : 216.4 kg
-Cooling system : 31.7 kg
-12V Battery : 15.9
-Exhaust system : 39.2 kg
-Fuel system : 63.3 kg
-Spare tire: 10.6 kg
I am considering Thundersky, CALB, GBS, Sinopoly and A123 battery.
Other components have not been selected yet.
I plan to design most of the project with CATIA V5, which I am quite familiar with. I want to be sure everything fits properly before starting to cut/weld the car chassis.
I have already contacted the SAAQ (The authority that registered cars in Québec), they provide me with a list (which I am not allow to share) of things required in order to register the converted car.
This thread will be my conversion built thread, I will post some photo as the projects go on!
I would like to have your advice/opinion on my project. About what I have planned and the results of my calculation and discuss it!
If some of you live somewhere close to Québec, Canada, I would like to have more specific advice for EV products dealers near me! For those from Québec, if any, your experiment with the registration process would be greatly appreciated!
EDIT 1 : Parts planning have changed (initially plan to use HPEVS AC50 and Curtis 1238).
EDIT 2 : This thread will be my conversion built thread.
EDIT 3 : Parts planning have changed (used to be kostov 9 or 11", Soliton 1 or jr and OEM manual transmission)