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575 Views 4 Replies 2 Participants Last post by brian_, Apr 25, 2019

billfunk29

Discussion Starter · Apr 24, 2019

I have been interested in EV conversions since the mid 90's. I have helped do machining of adapters and fabricating battery boxes on several conversions. Never done one for myself. I'd like to change that, since I have a 62 Corvair pickup begging for electric drive. I am also interested in axial flux motors. I would like to build one. I am weak on controls though. Would like a partner to build two systems.

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brian_

· #2 · Apr 24, 2019

The Corvair van is an interesting conversion target. If you just mount a motor in place of the engine (using the original transmission), there isn't a lot of space for battery modules. There are a few interesting possibilities:

replacing the engine and transaxle with a complete drive unit with the motor ahead of the axle line (if it fits) would leave the entire engine space for battery;
the transaxle appears to come apart into final drive and transmission sections, so the transmission could be replaced by the motor (and likely a reduction gear unit), keeping the final drive portion and leaving the entire engine space for battery; and,
the factory optional "level floor kit" could be used to create both a level load floor and a large battery compartment in the middle of the truck.

It would be a shame to lose the low floor and rampside loading, but the battery needs to go somewhere...

It's too bad that the van never got the car's improved rear suspension design - it stayed stuck in the first generation mechanical design (and body style).

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brian_

· #3 · Apr 24, 2019

billfunk29 said:
I am also interested in axial flux motors. I would like to build one.

That would be an interesting project, but that could stall the Corvair project for a very long time. Have you considered converting the van with an available motor, then building the motor as a follow-up project?

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billfunk29

Discussion Starter · #4 · Apr 25, 2019

Brian,
Thank you for the welcome and interest in the project. The Corvair is going to be, first, a metal shaping exercise. It is starting out as a van and will be converted into a 4 door pickup. This necessitates adding substantially to the wheelbase. That should provide for the battery space. The axial flux motor is a totally separate project. I will start posting in appropriate areas as I progress.
View attachment concept mosaicr.pdf

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brian_

· #5 · Apr 25, 2019

billfunk29 said:
The Corvair is going to be, first, a metal shaping exercise. It is starting out as a van and will be converted into a 4 door pickup. This necessitates adding substantially to the wheelbase. That should provide for the battery space.

That changes things substantially, as you won't have the (optional) rampside door (unless you build one) and you will presumably be building some sort of floor structure which (unlike the stock floor which is as thin as possible) could be designed to incorporate a layer of battery modules. You will need to decide whether the pickup box floor drops down ahead of the rear wheels (like the stock Corvair van and real Corvair pickup), or runs the entire length at engine cover level (providing some battery room ahead of the axle, or abandons the stock floor entirely and is built at some other level.

billfunk29 said:
View attachment 112481

You could build a 4-door pickup on the stock 95-inch wheelbase, but the box would be short, and it looks like you are going for a long box. I think you'll need substantially more cab length than shown, to fit usable rear doors and seat.

billfunk29 said:
I will start posting in appropriate areas as I progress.

I'm looking forward to the build thread(s).

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