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| Vehicle Name: | | Lightning Bug |
| Builder: | | caffinefiend |
| Started: | | 2011-11-15 |
| Finished: | | 2012-06-30 |
| Build Duration: | | 228 days |
| Build Hours: | | n/a |
| % Complete: | | 99% |
| Added: | | 2011-12-30 |
| Last Updated: | | 2012-07-22 |
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| Donor Vehicle: | | 1972 Volkswagen Beetle |
| Donor Cost: | | $500 |
| Conversion Cost: | | $2,500 |
| Total Cost: | | $3,000 |
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| - Performance and Range - |
| Max Power: | | 13 kW |
| Top Speed: | | 55 mph |
| Acceleration: | | moderate |
| Final Weight: | | 2300 lbs |
| Range at 30: | | 20 miles |
| Range at 55: | | n/a |
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| - Batteries / Charging - |
| Battery Type: | | Flooded Lead Acid |
| Battery Manufacturer: | | US Battery |
| Battery Configuration: | | 9-8v in series, us battery US8VGCHCXC,183 AMP HR 4 in front trunk, 5 behind rear seat. 630 lbs of floodies. |
| Battery Pack Voltage: | | 72v |
| Charger: | | Lester 36v modified to 72v |
| Charge Time: | | 6 hrs |
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| - Drivetrain - |
| Controller: | | CURTIS 1209B |
| Motor: | | 8" 36V DENSO/FORKLIFT 80 lbs |
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| - Accessories / Other - |
| DC-DC Converter: | | 12v battery & Chennic 72 to 12v |
| Air Conditioning: | | arm out the window |
| Power Steering: | | none |
| Brakes: | | none |
| Tires: | | |
| Other Notes: | | My first EV. Need 15 mile range and 35mph speed minimum. Still lining up the parts.Going with 72 volt system initially, but plan on going 96volt in a few years. ICE all gone,Coupler done, motor ready to go just need keyway on splined shaft, adapter done, ready. Working on 12v wiring, gauges running 0/2 welding cable front to back. Will update..........................................................................6/20/12 About 90% done now. Just finished installing the battery pack and cabling. Mounted the instrument cluster in dash to the left of the steering column. Went with Westech 0-100v meter, 0-500mp meter, 0-30V GE meter and 50-0-50 amp meter (12v). The motor is mounted to a 5/8ths adapter plate with lovejoy coupling welded to the clutch hub and motor shaft (10 tooth splined inny). Curtis 1209B is mounted to a 3/8ths 1.5'x2.5' aluminm plate along with the contator and the shunt and the 72v to 12v chenin isolated converter.
Still have to straighten out the 12v wiring, install the potbox and rig the unused clutch pedal and cable into an emergency pack decoupler. probably a few things yet I haven't thought of, but I'm close!..........................................................................6\30\12 It's ALIVE! First test runs today, after installing the 72v to 12v inverter and doing a ton of wiring. I now have a driveable EV! The motor runs hot and the amps are around 300 on acceleration from a stop when I juice it. Which keeps me on a par with the surrounding traffic. I can get up to 40 mph so far, and the battery pac is doing great. The conversion of my 36v lester to 72v
took less than an hour after I figured out how, my thanks to Pete (onegreenev). He mentioned in an earlier post about having done it. I think I may install a blower on the brushes for cooling, the internal motor temp was over 160 deg F after about five miles of stop and go driving culminating in the hill I live on. Also I have to get the brake lights working, upholstery, a few paint blemishes.. I guess it really is never 100 percent done, always more you can do!.................................................................07/04/2012
Got my brakes working correctly, replaced my lovejoy spider in the coupling with a higher grade- able to handle more torque. The original was rated at 90 ft lbs and got squashed pretty quick. The replacement is able to handle 400 ft lbs and is doing better. Drove about 8 miles today keeping the amps down around 200 on acceleration and the motor stayed much cooler...................................................07/12/2012
I've been commuting nights to work all week (12mile round trip) and it is sweet. I have adapted my driving style to a lower powered ev and am loving it. I still stay with the traffic, just accelerate a bit slower. I dared the freeway on a 10 pm run to work and hit 55 mph! I had to do it just to see. I maintained 50 up the few rises and a solid 55 on the flats and downhill. It takes 6 hours to recharge, starting at about 14 amps for the first 2.5 hrs, after which it slowly drops down to about 3 amps after 6 hrs. I have (just checked) 90 miles on my bug as an EV!................................................................7/22/2012
Now at 175 miles as an EV. Been on the freeway 3 times and can stay above 50 mph, often on level or slight down hill 55 and above. I commute at 10:30 pm so I'm not holding up traffic with my slightly slower speed, but I find that the motor is remaining fairly cool, and so I think I can safely go up to 96v without damage. I'm going to buy 3 more us battery 8v hc xc batterys and swap them through the system till I get a new controller so the batteries stay the same basic age. I'm still loving commuting in the LIGHTNING BUG! |
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| - Stats - |
| Page Views: | | 5361 |
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