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  #11  
Old 04-06-2012, 11:15 PM
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Default Re: Planning Mazda RX-7 conversion

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Originally Posted by matthieu149 View Post
ougingraham, do yo have a built thread or a web page? I would be interested to know more about your project!
Thank you!
I have a picassa photo album I update from time to time. I have a google doc that is more or less a journal which includes what I worked on that day. Here are the links:

The Photo album.

The journal.

I hope you find the photo album of some interest.

I have a big pile of stuff I still need to weigh. The list of stuff I have weighed as I removed it is at the very end. The one thing that surprised me most was the weight of the exhaust system.
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  #12  
Old 04-07-2012, 12:31 PM
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Default Re: Planning Mazda RX-7 conversion

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I think I'll go with a Kostov 9" 220V and the Soliton 1.
From 65 peak hp systems to a potential of over 150 hp..... Impressive change!

Really interesting album Doug. Do you have an explication to share about "Replacement armature for the WarP 9"
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  #13  
Old 04-07-2012, 12:38 PM
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Default Re: Planning Mazda RX-7 conversion

I'm not sure how well a Soliton 1 will go with a Kostov 9" 220v. I have my doubts about that motor would be able to handle 1000 amps for long. It's wound for higher voltage instead of higher amperage. I'm thinking it would take 280v better than it would take something near 1000 amps. There was another thread on this talking about dual motors where plamenator suggested running higher voltage and running out to higher RPMs rather than pumping gobs of amps. With a Soliton 1, I'd see if you can fit the Kostov 10". I'm personally looking to max out the voltage and go with a Sol Jr and Kostov 9" 220v.
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  #14  
Old 04-07-2012, 01:35 PM
Batterypoweredtoad Batterypoweredtoad is offline
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Default Re: Planning Mazda RX-7 conversion

According to this graph http://kostov-motors.com/files/produ...1f_S220E01.pdf

200V on a 220V K9 will carry 500A (130ft lbs of torque) to 4250rpms. Assuming a fairly constant rpm/volt relationship at 500A you are getting 21.25 rpm/volt. That means if you want to take that torque all the way out to 6000 rpm you need around 282 volts under load. That should be easy to achieve with a performance oriented pack and a Soliton Jr. You would have a 6000rpm power band instead of the 3000rpm powerband of the stock motor.
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  #15  
Old 04-07-2012, 04:29 PM
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Default Re: Planning Mazda RX-7 conversion

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Originally Posted by Yabert View Post
From 65 peak hp systems to a potential of over 150 hp..... Impressive change!

Really interesting album Doug. Do you have an explication to share about "Replacement armature for the WarP 9"
The first one had excessive runout at the end of the shaft. About 0.004" (0.1mm) and the spec is for about half that. I just got the replacement into the motor and measured it at 0.0008" (0.02mm) so I am now very happy. I was seeing about 0.010" (2.5mm) at the edge of the flywheel so I couldn't use it. This was both radial and axial so there would have been pretty terrible clutch chatter and it probably would have worn out the pilot bearing and the front transmission bearing in very short order. Netgain made it right and I have nothing but good things to say about them.
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  #16  
Old 04-08-2012, 04:31 PM
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Default Re: Planning Mazda RX-7 conversion

hi im from terrebonne. Not far from montreal. where do you live?
I have a vw corrado that im thinking of doing a conversion with!
would be great to meet up one day and talk
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  #17  
Old 04-14-2012, 03:15 PM
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Default Re: Planning Mazda RX-7 conversion

Next week, I will start to remove ICE components (engine, exhaust, cooling system and fuel system). I will measure the space and weight available.
If weight and space allow it, I'll go with the 11' and the soliton 1, otherwise I will go with the 9' and soliton JR.
Battery weight will of course be important, I would like to match my battery max discharge with my motor size!

If my battery pack cannot supply enough amp to max out the 11', would the additional low end torque worth the additional weight?
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Last edited by matthieu149; 04-26-2012 at 11:30 PM.
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  #18  
Old 04-15-2012, 08:18 AM
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Default Re: Planning Mazda RX-7 conversion

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Originally Posted by matthieu149 View Post
If weight and space allow it, I'll go with the 11' and the soliton 1, otherwise I will go with the 9' and soliton JR.
Battery weight will of course be important, I would lite to match my battery max discharge with my motor size!

If my battery pack cannot supply enough amp to max out the 11', would the additional low end torque worth the additional weight?
It looks to me like a WarP 11 will fit but without a lot of clearance. The WarP 9 fits fine although it it extends farther into the engine compartment than I was estimating.

The 12A motor produced 105 hp (78 kW) and 105 ft-lbs (144 N-m).

The 13B motor produced 135 hp (101 kW) and 135 ft-lbs (185 N-m).

A Warp9 can produce 105 ft-lbs at somewhere around 600 to 650 amps and over 150 ft-lbs at 1000 amps. At 1000 amps and 192 volts a Warp9 will be producing approximately 170 hp at the shaft. At 600 amps and 192 volts will produce approximately 120 hp. That is estimated, probably someone has better numbers but those are going to be representative. With that in mind I chose a WarP9 rather than the WarP11 for my project. I am concerned that the stock drive train will be stressed even with a WarP9. The WarP9 should be plenty for this car as the performance should be a bit better than with the 13B engine unless the car gains a lot of weight from too many batteries. I am using 54 or 56 100AH cells which will end up adding only a few pounds over the stock weight of the vehicle. I ended up with a Soliton 1 rather than a Jr because you can turn down the current on a Soliton 1 but you can't turn up a Jr above 600 amps.

I am about 90% confident that a WarP 11 will fit, but the extra weight and the weight of the extra batteries to get the higher currents and the fact that the drive train wasn't designed to handle that power level it seemed more prudent to use the smaller motor.

I think the AC50 and 650A Curtis would also be excellent in this car although it is on the high end of the weight scale for that setup.

I think the additional low end torque of the WarP11 would be wasted destroying clutches and smoking the tires.
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  #19  
Old 04-15-2012, 08:45 AM
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Default Re: Planning Mazda RX-7 conversion

Quote:
Originally Posted by dougingraham View Post
...
A Warp9 can produce 105 ft-lbs at somewhere around 600 to 650 amps and over 150 ft-lbs at 1000 amps. At 1000 amps and 192 volts a Warp9 will be producing approximately 170 hp at the shaft.....
Just a quick correction/FYI. Our hydraulic dyno has two WarP-9 motors in tandem and each delivers approximately ~240lb-ft of torque at 1000A. There is some variation from motor to motor, so call it 230-250lb-ft of torque at 1000A.

The WarP-9 requires ~50V for every 1000RPM and is in imminent danger of immediately zorcching (ie - a plasma flashover across all of the brushes) at about ~3000rpm (ie - 150V). In other words, the maximum amount of input power a WarP-9 can handle is about 150kW. I'm sure some drag racers have pushed that a *little* bit higher, but for a daily driver I wouldn't let a WarP-9 see more than 192V or more than 130-140kW (110-120kW highly suggested for new EV drivers). NB - the Soliton controllers let you specify a maximum motor power limit, as well as maximum motor voltage and current, and RPM (must hook up a tach pickup, of course, for the latter function to work).
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Last edited by Tesseract; 04-15-2012 at 08:49 AM. Reason: Reword zorch...
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  #20  
Old 04-15-2012, 09:29 AM
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Default Re: Planning Mazda RX-7 conversion

Which numbers are correct? 150V max, or 192? 3k RPM or 3840?
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