I have been in and out of this forum for about 3 months researching and I thought it was about time that I started my own build thread. Bear with me as this build will be slow. I am a 30 year old mechanic for a pharmaceutical industry also a Navy Reservist. I am a believer in sustainability and using resources efficiently and responsibly. I was a Diesel Mechanic for the Navy Active Duty for 6+ years and modified cars as a teenager.
The project is to make the most efficient car with respectable performance, range, and looks. To do this weight is my enemy. I found a light sporty car now I’ll need to trim the fat even more. This project will not be done until 2013 for many reasons. It is a project, a have a family, and I have a job so balanceing time is important. Also the availability of the 144V AC controller and the price of the batteries push the date out to then.
Kelmark GT fiberglass kit car on a 78 VW chassis (Ferrari Dino Replica) This car will be built for local car shows and car audio shows.
I was unable to get the exact curb weight before starting but a stock VW beetle weighs approx 1800lbs and this car is likely 300lbs less so my guess is 1500lbs starting weight. Goal Finished Curb Weight <1600lbs
Drag Coefficiant 0.34
Frontal Area 21.9 sq ft
I see that the stock curb weight of a Kelmark is 1700lbs according to the blueprint. My revised finished weight is to stay at around 1700 lbs which means I need to find additional ways to reduce weight.
Modifications include
Stripped the chassis, replaced floor pans, welded a 3” body lift kit (to increase headroom and add strength to the pan), trimmed any excess metal, changed the head on chassis from ball joint to link pin, and lastly painted.
Purchased
ü Lightweight aluminum beam front beam assembly
ü 4 wheel disc brake kit (still need to machine to reduce weight)
ü All new suspension components
ü New performance transaxle (stock gearing)
ü Racing seats
Looking into;
o Lightweight Flywheel/ and HD Clutch
o Light weight rims and LRR tires
o Lightweight custom interior and stereo
o Reducing weight of fiberglass body
o Race windshield?
The Kit to be used
HPEV AC-50 (Hoping for a 144V controller by the time I am ready)
The Batteries
Dow Kokam SLPB 75106100 (QTY960)
7.5 AH 3.7V 15A Cont
Dimensions; .30 x 4.17 x 3.94 = .34 pounds
40 cells wired in series = 148V Nominal-166V Charged 7.5AH pack 15A cont. = 13.6 pounds
24 packs of 40 is 148V, 180AH, 360A cont 900A peak = 326 pounds
Instrumentation
The Display, stereo, GPS, Cameras, and security: MiMod- www.evinstuments.com
Series Hybrid
This will be a range extender or a way to charge when there is no access to a plug in. “Mainstream produces the world's lightest 2-kW diesel-powered electric generator. The generator is a completely integrated system optimized for size, weight, noise and reliability. This generator is not merely the coupling of a commercial off-the-shelf diesel engine and alternator.” Around 100 lbs and is more efficient and durable than gasoline generators.
Debating on whether to permanently install or have it removable when not needed.
http://www.mainstream-engr.com/products/engines/
Solar
I would like to be able to get a 3 mile per day charge from thin solar cells installed on top of the car. Still in planning phase, need to research more on how to install and which cells will give the best bang per buck. Also need to determine how much my car will use at 35mph for 3miles.
The project is to make the most efficient car with respectable performance, range, and looks. To do this weight is my enemy. I found a light sporty car now I’ll need to trim the fat even more. This project will not be done until 2013 for many reasons. It is a project, a have a family, and I have a job so balanceing time is important. Also the availability of the 144V AC controller and the price of the batteries push the date out to then.
- My skill level with auto mechanics and fabrication is above average.
- The range (75-85miles at 70mph 75%DOD hybrid) (50-60miles at 70mph 75%DOD EV)
- The level of performance you are hoping to get is <15s 0-60
- Budget $25,000 + tax breaks + sponsors + friends
Kelmark GT fiberglass kit car on a 78 VW chassis (Ferrari Dino Replica) This car will be built for local car shows and car audio shows.
I was unable to get the exact curb weight before starting but a stock VW beetle weighs approx 1800lbs and this car is likely 300lbs less so my guess is 1500lbs starting weight. Goal Finished Curb Weight <1600lbs
Drag Coefficiant 0.34
Frontal Area 21.9 sq ft
I see that the stock curb weight of a Kelmark is 1700lbs according to the blueprint. My revised finished weight is to stay at around 1700 lbs which means I need to find additional ways to reduce weight.
Modifications include
Stripped the chassis, replaced floor pans, welded a 3” body lift kit (to increase headroom and add strength to the pan), trimmed any excess metal, changed the head on chassis from ball joint to link pin, and lastly painted.
Purchased
ü Lightweight aluminum beam front beam assembly
ü 4 wheel disc brake kit (still need to machine to reduce weight)
ü All new suspension components
ü New performance transaxle (stock gearing)
ü Racing seats
Looking into;
o Lightweight Flywheel/ and HD Clutch
o Light weight rims and LRR tires
o Lightweight custom interior and stereo
o Reducing weight of fiberglass body
o Race windshield?
The Kit to be used
HPEV AC-50 (Hoping for a 144V controller by the time I am ready)
The Batteries
Dow Kokam SLPB 75106100 (QTY960)
7.5 AH 3.7V 15A Cont
Dimensions; .30 x 4.17 x 3.94 = .34 pounds
40 cells wired in series = 148V Nominal-166V Charged 7.5AH pack 15A cont. = 13.6 pounds
24 packs of 40 is 148V, 180AH, 360A cont 900A peak = 326 pounds
Instrumentation
The Display, stereo, GPS, Cameras, and security: MiMod- www.evinstuments.com
Series Hybrid
This will be a range extender or a way to charge when there is no access to a plug in. “Mainstream produces the world's lightest 2-kW diesel-powered electric generator. The generator is a completely integrated system optimized for size, weight, noise and reliability. This generator is not merely the coupling of a commercial off-the-shelf diesel engine and alternator.” Around 100 lbs and is more efficient and durable than gasoline generators.
Debating on whether to permanently install or have it removable when not needed.
http://www.mainstream-engr.com/products/engines/
Solar
I would like to be able to get a 3 mile per day charge from thin solar cells installed on top of the car. Still in planning phase, need to research more on how to install and which cells will give the best bang per buck. Also need to determine how much my car will use at 35mph for 3miles.