Hi Pete and nice to meet you. I know it is a long thread, but dont just read the first post - there are many upgrades along the way (DC/DC converter, vacuum pumps, bigger vac reservoir). I ended up with 46X200AH LIFPO4 cells, Zilla Z1KHV controller and Warp 9 motor, and an Elithion BMS - all are still in use.
I would consider a more modern AC drive and controller (instead of DC brushed motors) - it is not a huge ordeal to maintain brushes (blow the dust from motor out 2 times a year, pulled motor out and switched brushes once since 2009) but the "direct short" aspect of DC controllers is not present in AC controllers. I think this would also lead to better overall efficiency - suprisingly it may be still hard to find high power AC motors and controllers I think (so if you can live with lower performance it is much less expensive, and much easier on your batteries). Using AC would mean a higher DC voltage and lower AH cells. I would not consider using lead acid batteries - although tempting due to lower initial costs, they are heavy/bulky, short life, maintenance needed etc...
Although some things have "moved on" - surprisingly the cost of LIFEPO4 large format cylindrical cells have not changed - virtually the same cost today as it was in 2009 (which due to inflation means some small reduction). If you can get cells from a salvage vehicle (leaf etc.) that would reduce costs. If you need 50 miles, you will need a pack bigger than mine - cold weather reduces range, and over time the range reduces as well. My pack started at about 100 kM, but is down to 50-60 now - this degradation can be minimized by adding insulation and heating pads on day 1 (ie do not charge when it is cold). I would even add an interlock to disable charging unless the cells are above 0C. The charge port should be standardized now - J1772 etc.
I would still go wtih a BMS (for monitoring cells as a minimum) - maxwell DC/DC converter has been awesome. Charger and Zilla controller are still supported by Manzanita (they have been great) but there are other less expensive options now. Hopefully you can find a quieter vaccuum pump and power steering hydraulic pump. Do put in a large vacuum reservoir - my original 4" ABS tube was too small (and lead to a scary sensation when the power brakes loose vaccuum from a hard brake and it is back to manual) - all good with a larger ABS vac reservoir.
A RAV4 has been a perfect match for my needs (ie small SUV to carry hockey stuff, kids etc, AWD in winter etc.) - that said it does not have the cool factor. It is a good daily driver, but for the amount of cost/effort to convert, make 100% sure that it is the correct vehicle for you. My 2001 has been updated with a touchscreen, android head unit etc.. but it is still a 20 year old vehicle - if you can find something newer it would be better. A lot of money to convert, so using a newer donor would make sense. I dont think they still make standard transmissions in newer RAV4s (at least not available in Canada) - manual transmissions are a lot more popular in the UK so hopefully you can find one.
All the best on your conversion - make sure to add a build thread!
Garth
I would consider a more modern AC drive and controller (instead of DC brushed motors) - it is not a huge ordeal to maintain brushes (blow the dust from motor out 2 times a year, pulled motor out and switched brushes once since 2009) but the "direct short" aspect of DC controllers is not present in AC controllers. I think this would also lead to better overall efficiency - suprisingly it may be still hard to find high power AC motors and controllers I think (so if you can live with lower performance it is much less expensive, and much easier on your batteries). Using AC would mean a higher DC voltage and lower AH cells. I would not consider using lead acid batteries - although tempting due to lower initial costs, they are heavy/bulky, short life, maintenance needed etc...
Although some things have "moved on" - surprisingly the cost of LIFEPO4 large format cylindrical cells have not changed - virtually the same cost today as it was in 2009 (which due to inflation means some small reduction). If you can get cells from a salvage vehicle (leaf etc.) that would reduce costs. If you need 50 miles, you will need a pack bigger than mine - cold weather reduces range, and over time the range reduces as well. My pack started at about 100 kM, but is down to 50-60 now - this degradation can be minimized by adding insulation and heating pads on day 1 (ie do not charge when it is cold). I would even add an interlock to disable charging unless the cells are above 0C. The charge port should be standardized now - J1772 etc.
I would still go wtih a BMS (for monitoring cells as a minimum) - maxwell DC/DC converter has been awesome. Charger and Zilla controller are still supported by Manzanita (they have been great) but there are other less expensive options now. Hopefully you can find a quieter vaccuum pump and power steering hydraulic pump. Do put in a large vacuum reservoir - my original 4" ABS tube was too small (and lead to a scary sensation when the power brakes loose vaccuum from a hard brake and it is back to manual) - all good with a larger ABS vac reservoir.
A RAV4 has been a perfect match for my needs (ie small SUV to carry hockey stuff, kids etc, AWD in winter etc.) - that said it does not have the cool factor. It is a good daily driver, but for the amount of cost/effort to convert, make 100% sure that it is the correct vehicle for you. My 2001 has been updated with a touchscreen, android head unit etc.. but it is still a 20 year old vehicle - if you can find something newer it would be better. A lot of money to convert, so using a newer donor would make sense. I dont think they still make standard transmissions in newer RAV4s (at least not available in Canada) - manual transmissions are a lot more popular in the UK so hopefully you can find one.
All the best on your conversion - make sure to add a build thread!
Garth
