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Discussion Starter · #1 · (Edited)
Hi everyone,

After signing up it seemed like a good idea to introduce ourselfs. We (several people will be using this acc if that's allright) are a group of 7 dutch Automotive Engineering students. Our latest project is an EV conversion of a Saab 99. We just got started this week, and the coming 8 weeks will all be going into research. We happend to come accros your forum. Love the great pieces of real world information you guys have out here.

Now about the conversion. The car is a 1984 saab 99. We didn't get to pick it, the customer has owned the car since 1984, has driven 960.000kms (!) with it, and is now looking to do an EV conversion. We were asked to figure out the best solution for the conversion. His wishlist would pretty much be as follows: 120kmh/75mph top speed. 0-60 in 20 seconds is considerd acceptable. All this with as much range as the €30k budget would allow. So far we haven'tgot a clue how we are going to achieve this, but we'll have to start somewhere ;)

The following weeks we'll be doing research, and once we get to the actual build part, we'll open up a project thread.

Quick edit: After looking though the project threads it seems like most guys here prefer to keep the standard gearbox and clutch assembly (am I right?). With the Saab this is where we would hit a snag. The car is an FF layout, with the engine sitting legthwise above the gearbox.



The owner has been doing some research himself and figured out it would be very difficult to just fit an electric motor in the place of the current combustion engine. Is it a whole lot harder to ditch the entire gearbox/clutch assembly, and make it a "direct drive"?
 

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Is it a whole lot harder to ditch the entire gearbox/clutch assembly, and make it a "direct drive"?
Hi - normally you keep the diff for a "direct drive"

I'm pretty sure your SAAB has a separate oil system for the gearbox so you should be able to remove the engine and replace it with an electric motor
The issue is going to be the drive-line center-line, is it high enough to get a motor in there??
Best would be a 9 inch motor in which case you need 4.5 inches 114mm clearance

I would recommend stripping it out and seeing what gets in the way - and can you grind it off!

It is a bit more work but you could look at ditching the input gears and going belt (or chain) drive to the input shaft
That would mean there would be plenty of room for the motor

AC verses DC - depends on your budget
AC is superior BUT expensive or wimpy or both
DC is cheaper - and much more grunty

Edit
Looking back at your schematic you should have plenty of room for the motor, don't forget you don't need a flywheel
and there are two views on whether a clutch is needed
 

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Your customer's top speed and 0-60 time could easily be met with an AC76 or AC75 motor with 144V controller from HPEVS, if you prefer an AC induction motor. If you prefer DC, most here use the Netgain WarP9 9" series DC motor. Skooler in the UK will be happy to sell you LiFePO4 batteries. Can't say much for battery requirement without knowing details of the car, especially weight, but with that budget you should be able to afford at least a 28kWh pack. Good that you plan to spend the next several months on research. Check out what the vendors on the RHS of your screen offer and do your own calculations. Don't listen to any one of us too much as we are all biased.
 

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Discussion Starter · #7 ·
Loads of research have been done. We will probably keep the original gearbox. If we have more original bits, the Dutch roadworthy tests will be easier to pass.
Our current leading idea would be an Emrax motor, using a Unitek controller. The major advantage of the Emrax is the small size. This would allow it to fit in front of the gearbox, so you could just tie them together. Rather then having to use a complicated chain, belt or gear drive. So far I can't really find a whole lot of projects using this setup. What would be your "professional" opinion, on using this on our car?
 
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