[dragonsgate]

I never even considered looking at or suggesting a used conversion but that is a very good idea. I would still emphasize the need to go over the purchase and check everything out before you buy. It could save some time and possibly money if you do it right. As for the way something looks I guess terrible is a matter of perspective. For example... Rat Rods interest me and some of them look cool but I couldn’t own one and be happy. I have spent too much of my life putting shinny paint jobs on all my vehicles.

[laminator]

You can save money on batteries by using flooded lead acid deep cycle batteries. They are cheapest but last the least of lead acid batteries. The number of cycles depends on the depth of discharge. If you can afford gel or AGM lead acid batteries, they are still cheaper than lithium.
Yabert said
>5-6 Kwh of lithium cells. That represent 2-3K$
found 7kWh of flooded lead acid deep cycle that represents 1.2k$
AGM lead acid, almost twice as much
You can also save money by using a DC motor and making your own controller from scratch if you know about something electronics(GTO thyristors and a PWM modulator(simple circuit)).
And as others indicated, using used parts from forklifts are a way to go on budget.
If you use sepex(separately excited) DC motor and a controller that allows Regenerative Braking, you can extend your range.
And if you would want to increase the range even more, you can overpressurize your wheels so they have less Rolling Resistance . That's what I do on my bicycle so I don't have to peddle that hard.

[Coley]

If you start with a small front wheel drive car that is sound in body, but bad in engine, use a new controller, run 72 volts, use an 8-10 HP, DC, fork lift motor,and GEL batteries, you should be able to do it for a little over $2K.

25 miles is easier to do at 45mph than 55mph.

I did my Yugo for 1K. The batteries will be the most costly part.

Make your own adapter plate and coupler. Sell off as much of the removed parts as possible. Radiator and heater core etc, for scrap.

Install new brakes, use the original stick shift trans, spare tire is optional as is the jack. keep the interior, but remove rear seat, make your own cable ends, buy a good charger.

Shop swap meets, hamfests (for electronic supplies), wrecking yards, etc.

Build with safety in mind. Finish off all modifications, so they look good.
Low cost doesn't have to look crappy.

Then enjoy your EV smile....

[Aelwero]

Originally Posted by dragonsgate

Even though it might sound like it, this is not intended as a personal attack, but…when you say”I don’t care if it looks like a crap-bucket” it dose not translate well. I interpret that as I am not above taking short cuts to get a car on the road. I still think $2k is unrealistic for a safe and reliable car even if you had a sound car with good brakes. Even if you managed to get something on the road what is the message a rust bucket rattletrap electric car going to send out to the public at large. Putting supper low budget unsafe electric cars on the road will do nothing but hurt the credibility of the DIY electric car community as a whole. I am not against you having or building an electric car. I just hope your top priorities are higher than just how CHEAP you can make it.

I'd say the exact opposite would happen... The current public opinion of EV's is that they are not capable of ever being a cheap"hooptie" (because the batteries have to be replaced), and therefore are completely out of reach of the people who drive "hoopties", and there are a lot of folks in that income bracket... a rolling rust bucket electric hooptie would go a long way towards making EV's look like an "anybody/everybody" option IMHO.

[jeremyjs]

Originally Posted by laminator

You can save money on batteries by using flooded lead acid deep cycle batteries. They are cheapest but last the least of lead acid batteries. The number of cycles depends on the depth of discharge. If you can afford gel or AGM lead acid batteries, they are still cheaper than lithium.
Yabert said
>5-6 Kwh of lithium cells. That represent 2-3K$
found 7kWh of flooded lead acid deep cycle that represents 1.2k$
AGM lead acid, almost twice as much
You can also save money by using a DC motor and making your own controller from scratch if you know about something electronics(GTO thyristors and a PWM modulator(simple circuit)).
And as others indicated, using used parts from forklifts are a way to go on budget.
If you use sepex(separately excited) DC motor and a controller that allows regenerative braking, you can extend your range.
And if you would want to increase the range even more, you can overpressurize your wheels so they have less rolling resistance . That's what I do on my bicycle so I don't have to peddle that hard.

7 kwh of lead does not equal 5-6 kwh of lithium. you'd need at least double the capacity of the lithium to get a similar range when brand new. To say nothing about a year or two down the road as the leads go south.