DIY Electric Car Garage

Vehicle Name:		ZX2EV
Builder:		PatricioIN
Started:		2008-09-28
Est. Finish:		2008-12-01
Build Duration:		64 days
Build Hours:		n/a
% Complete:		90%
Added:		2008-09-26
Last Updated:		2008-11-30
Main Build Thread

Donor Vehicle:		1998 Ford ZX2
Donor Cost:		$2,500
Conversion Cost:		$9,500
Total Cost:		$12,000

- Performance and Range -
Max Power:		48 kW
Top Speed:		80 mph
Acceleration:		average
Final Weight:		3200 lbs
Range at 30:		50 miles
Range at 55:		40 miles

- Batteries / Charging -
Battery Type:		Flooded Lead Acid
Battery Manufacturer:		Interstate
Battery Configuration:		8 in engine compartment, 7 in trunk
Battery Pack Voltage:		120v
Charger:		Quick Charge 120V 10A with Select-A-Charge
Charge Time:		8-10hrs

- Drivetrain -
Controller:		CURTIS1221C 7401
Motor:		ADVANCED DC 203 06 4001A

- Accessories / Other -
DC-DC Converter:		HWZ Series 25a 300w
Air Conditioning:		removed
Power Steering:		Toyota MR2 pump
Brakes:		Electric vacumn
Tires:		Will look at later
Other Notes:		9.25.08 Vehicle purchased and working on ordering parts. 9.28.08 Got started on the dismantle today. 10.02.08 Most everything out of motor bay but the block. Gas tank removed. Parts ordered and on the way. Keeping log of all costs hours spent weight removed and taking pictures and doing some video. 10.03.08 Got exhaust and heat shields fuel and emission lines out today. Got halfshafts undone and pretty much all ready to rent hoist and pull the beast. 10.06.08 40 minutes to go get engine hoist. Ten minutes to assemble and remove bolts and nuts on engine mounts. Two minutes to remove engine. The beast is out!! 10.07.08 Removed clutch flywheel clutch assembly. Measured magic number. Cleaned tranny. 10.08.08 Cleaned motor compartment up today. Paint in great shape. 10.09.08 Advanced DC 203-06-4001A motor arrived today! 10.15.08 Got coupler back from machinist and he did a great job! 10.17.08 Have decided to make adapter myself and have ordered aluminum plate. 10.19.08 Removed clutch master cylinder and made some battery mockups for placement. 10.21.08 Made adapter mockup out of particle board. Controller and other components came today. Aluminum for adapter came. 10.22.08 Made adapter plate and motor plate. Just need to mate the two. 10.23.08 Mated and drilled alignment holes for adapter and spacer plates today but have a slight vibration that I need to work out. A minor obstacle I am sure I can correct. 10.25.08 Finished adapter plate and did some misc cleanup. Motor and tranny ready to be reinstalled. 10.26.08 Installed electric motor and tranny today along with reinstalling wheel assemblies halfshafts and crossmembers. 10.29.08 Spent about three hours trying to figure out a model for the passenger side motor mount. Slow going. 11.3.08 Dropped off motor mount at welder. Cut out trunk floor for battery rack. Made template for PS pump bracket. Placed GFI outlet in trunk for charger. 11.04.08 Work on component placement. Test fit finished motor mount. Work on power port plug. 11.05.08 Prime and paint motor mount. Work on mounting ammeter and voltmeter. 11.07.08 Spent a couple of days running around getting parts and finding solutions to heater and ps issues. Have custom ps pressure line finally. Have everything I need to install heater and meters. 11.10.08 Work on ceramic heater and power port. Refill tranny fluid. 11.12.08 Wire heater. Install heater and dash. Move accessory power port. Run wire for voltmeter. 11.13.08 Cut metal for trunk battery box support and took to welder. Wired power to volt and ammeter. Ran load lines for those and Curtis fuel gauge. Fit welded rear battery box support in trunk. Reinstalled lower dash. 11.14.08 Intalled Curtis fuel gauge in instrument cluster. 11.17.08 Receive batteries. Paint rear rack. Work on rear box. 11.18.08 Work on rear battery box. 11.19.08 Work on rear battery box. Deliver front frames to welder. Repair and bleed cut brake line. 11.20.08 Finished securing seven batts in trunk box. Relocated washer fluid reservoir. Worked on design of front batt rack. 11.21.08 Deliver front most rack to welder. Get steel for middle rack. Work out 12v heater switch connections. 11.23.08 Wire and place 12v heater switch. Fix cigar lighter. Explore why horn and power mirrors not working. 11.24.08 Raise rear box 2 inches. Spray foam in trunk floor openings. Install front battery rack. 11.25.08 Design and build middle rack over motor with welder. Cut extra screws off battery posts. 11.26.08 Paint middle rack. Wire plumb and mount MR2 PS pump. 11.27.08 Install middle rack. Begin custom cables. 11.28.08 Secure front batts. Fabricate cables. Connect batts. 11.29.08 Mount charger. Run charger wire under car in counduit. 11.30.08 Work on control wiring.

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