Quote:
Originally Posted by Tedktis
In an effort to help people on their first build I have put a complete list, or what I believe to be. Some of these other so called "complete" kits for sale through vendors or individuals are missing so many parts. I am on my first EV build and wish there were a post (maybe there is?) which gave a list of most, if not all, of the components needed. I thought I would list the parts I am using in my DC conversion.
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1. DC motor that will have enuf power for the weight of donor car.
Warp 9 ($1900 w/shipping)
2. Controller with appropriate voltage, amps and features you require for your build.
Netgain HV Industrial Controller? ($2500 
)
3. Charger to charge batteries (make sure the voltage and battery type work with your batteries)
More research needed
4. Batteries, lead or lithium, costs can be expensive for battery packs
Lithium 100 Ah, 120V or 144V, Probably Sinopoly or CALB. (
$4800-$6000)
5. BMS(?) Battery Management System
More research needed
6. Controller box with electric cooling fan to house controller and other electrical components.
I have a metal box for electrical stuff that might work. I have metal industrial computer fans to work on switched 12V ($0)
7. Liquid cooling kit(?)
I guess, it seems like poor engineering to me ($80, I can reuse parts and build this most likely.)
8. Pot box, throttle lever that tells controller the throttle position.
Hall Effect throttle assembly ($185)
9. Main contactor for the ignition key to activate the electric drive
More research needed
10, Reverse contactors(?) if you want to have the motor spin backwards if there is no reverse in transmission
I plan on using the transmission to put it into reverse ($0)
11. Main fuse with holder for circuit protection etc
More research needed, It will go into electrical box
12. 2/0 gauge 600 volt cable wire to connect the motor, controller and batteries.
Yes, with conduit ($100)
13 heat shrink and rubber boots for wire and lugs
Yes ($10)
14. Battery lugs or bus bars depending on which batteries used.
Yes ($110)
15. Adapter and coupler for motor-to-transmission.
Both a adapter plate and a threaded coupler I guess ($300 DIY, $1000 done this week)
16. DC-DC converter or accessory battery to power low voltage system
More research needed, some days I like the DC-DC option better, others it is the 12V battery ($250)
17. Battery boxes
- Yes ($200)
18. Circuit breaker for maintenance or emergency
Yes, main disconnect switch
19. Voltmeter
20. Ammeter
21. Other meters (?)
22. Shunt (?)
23. Mount for meters(?)
24. Speed sensor for motor rpm
- Yes, it mounts on the shaft ($95)
25. Heater(?)
- Yes, but only a space heater plugged in when in the garage in the morning. ($0)
26. A/c system(?)
- No, I'll have the vent fans. I could see adding ice to a cooler and blowing that cold air around, but it is not needed. ($0)
26. Vacuum pump for power brakes(?)
Yes ($425)
27. Pulley for power steering(?)
- They also make a pump ($850 )
28. Other relays (?)
29. Other fans for cooling or heat sinks(?)
30. Inertia switch(?)
31. Motor temp gauge/switch(?)
32. Motor mounts(?)
($150)
33. Controller pre-charge resistor(s) if required(?)
34. Tools, especially for cutting and crimping HV wiring
I can borrow tools
My additions
35. Aluminum flywheel ($400)
36. LED tail lights ($250)
37. Digital gauges
38. Back to the future flux capacitor ($35)
39. NGC motor Interface? ($300)
40. iPhone/ipod cable to amplifier
41. Fiberglass bed, bumper, and possibly hood $1286
42. Line-X bed liner $500
$14,726, and that is before the fuses, contactors, and any other odds and ends with the smaller 120V pack. A little over my $10k estimate...
I will work more on piecing together all of these parts over Labor Day weekend. To be honest, the electrical stuff looks a lot easier to me than the removal part and repair has been.
Re: Complete Electric DC Conversion Kit
Linear Mode
