Patrick Roth's zx2EV project

60008 Views 359 Replies 38 Participants Last post by PatricioIN, May 24, 2021

PatricioIN

Discussion Starter · Sep 28, 2008 (Edited)

4

Ok, I couldn't wait for parts, so I got started.

I weighed car at local scales the day after purchase: 2500lbs curb (1600F/900R)

My conversion is a '98 Ford zx2 in fantastic condition with all the options. I started a website to document the process, have filmed my first video and have begun to dismantle the donor. All can be seen here:

http://www.cardomain.com:80/ride/3155482

http://www.youtube.com/watch?v=eKaqRKZn2sQ

and I'll keep 'em coming!

Patrick
Indy

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PatricioIN

Discussion Starter · #2 · Sep 28, 2008 (Edited)

today:

took measurments of wheel wells, removed hood, removed most accessories that aren't staying.. kept log, took pics, weighed everything that was removed.. put up some components on craigslist to (hopefully) recoup a little cash!

If you want to go into my EVproject email group, send me a pvt with your email address.

oh, one other thing...

Gavin, thanks! This is pretty much all inspired by your website... well, ok, not the idea of having an EV, but certainly the rest of it!!

You know what they say: Imitation is the highest form of flattery.

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JSRacer

· #3 · Sep 28, 2008

Hey Patrick, looking forward to seeing the You Tube videos. Gavin is definitely an inspiration to many including myself. I'm gonna keep checking back on this thread to see your progress!

Josh

TX_Dj

· #4 · Sep 29, 2008

JSRacer said:
Hey Patrick, looking forward to seeing the You Tube videos. Gavin is definitely an inspiration to many including myself. I'm gonna keep checking back on this thread to see your progress!

Josh

No kidding, Gavin's youtube videos inspired me to get back on the bandwagon after having abandoned my last two EV conversions nearly 10 years ago due to financial constraints. Now I have the truck AND I'm re-converting my scooter... it's addictive, I know this, because in the back of my mind I'm already thinking about how the heck I'm going to build a DRAGSTER... lol

TelnetManta

· #5 · Sep 29, 2008

That is one NICE looking little car. May I ask what you paid for the donor? I'm already thinking about my second one

Ben in SC

PatricioIN

Discussion Starter · #6 · Sep 29, 2008

TelnetManta said:
That is one NICE looking little car. May I ask what you paid for the donor? I'm already thinking about my second one

Ben in SC

$2500... Much more than I wanted to for a donor, but it is (was) in very good running condition and is EXTREMLY clean inside and out along with being fairly new and well optioned.

dtbaker

· #7 · Sep 29, 2008

It might be a case of the the blind leading the blind, but I am building a website along parallel lines.... with the goal to inspire the 'common person' to give conversion a shot. All I have to note is that the limiting skill so far was not the electronics (which I fear) but the welding and fabrication of battery racks and motor mounts, which I can handle....

IF you wanna have a look at my site for generic information, feel free, but since I am working on a different vehicle, the specifics won't apply.

anyway, have fun!

D

PatricioIN

Discussion Starter · #8 · Sep 29, 2008

dtbaker said:
It might be a case of the the blind leading the blind, but I am building a website along parallel lines.... with the goal to inspire the 'common person' to give conversion a shot. All I have to note is that the limiting skill so far was not the electronics (which I fear) but the welding and fabrication of battery racks and motor mounts, which I can handle....

IF you wanna have a look at my site for generic information, feel free, but since I am working on a different vehicle, the specifics won't apply.

anyway, have fun!

D

Your site is great, terrific detail! I like the placement of the vacumn pump, may have to copy that.

dtbaker

· #9 · Sep 29, 2008

thanks... I was looking for a place for the vacuum pump that would not cause a lot of vibration. anyway, thae current project is to design the under-hood rack for two more batteries. I am pretty sure it is going to require a hood 'scoop' of some kind, but what the heck I am committed to the usgc8vgchx batteries.

d

PatricioIN

Discussion Starter · #10 · Sep 30, 2008 (Edited)

update on day 2:

ok, well not a whole lot done today. Mainly just a bit more disassembly.. various pieces and hoses and brackets, etc.. Acutally, I keep looking at the engine and wondering if maybe I should pay a professional to take that out.. It would be much quicker and simpler. I wouldn't have to buy/rent a hoist, etc.. and since there is a neighborhood garage only one block away.. well, we'll see. I've never taken out an engine before and am feeling a bit intimidated by that part!

latest tidbit: http://www.cardomain.com/ride/3155482/3

STILL trying to place an order with KTA for the majority of my components... they must be very busy right now..

TelnetManta

· #11 · Sep 30, 2008

PatricioIN said:
I've never taken out an engine before and am feeling a bit intimidated by that part!

Taking an engine out is the easy part, it's putting one back in that's actually a little difficult

Don't sweat it, its the best way to get to know the car and it's actually the hardest "physical" part of the conversion. I had to use a lift to install my motor so I had to have one anyway.....

Ben

PatricioIN

Discussion Starter · #12 · Sep 30, 2008

TelnetManta said:
Taking an engine out is the easy part.....

Ben

haha!! so you say! Yeah, I'm sure I can do it.. eventually!

TX_Dj

· #13 · Sep 30, 2008

Actually, at this moment I'm starting to think that wiring all the 12v systems back up properly will be a bigger challenge than removing the engine was. While disassembling, I thought to myself "I know what I'm doing, I'll remember where each connector went" and didn't bother to label everything. GM color-codes the connectors, so it should be easy to figure it out later on, especially considering where the wiring connector lays on the frame of the vehicle.

Do yourself a favor... label everything as to where it came from. You can get a brother P-touch labeller brand new with 2 tape cartridges and enough battery to run it for a year or more on ebay for $30 with free shipping.

PatricioIN

Discussion Starter · #14 · Sep 30, 2008

yeah, that much I got covered, but I'm doing the cheapo route.. masking tape doubled over each wire!

actually.. can you think of any reason I would need the PCM post conversion??? someone offered to buy it off me.

JSRacer

· #15 · Sep 30, 2008

Pat, you may want to give EV-America a call unless you're loyal to KTA.

PatricioIN

Discussion Starter · #16 · Oct 1, 2008 (Edited)

funny thing.. only about an hour after I posted today I got an email from Wistar Rhodes of KTA with this:

Advanced DC motor 203-06-4001A 1,411.00

Curtis Controller 1221C-7401 1,050.00

Albright SW-200B/3-13 Contactor 80.00

GE Circuit breaker 162.00

Switchplate 20.00

Curits fuel gauge 225.00

Magnacraft relay 16.00

Waytek barrier strip 10.00

Magna welding lugs 50.00

Magna terminal clamp + 45.00

Magna terminal clamp - 45.00

Rubber clamp cover + 24.00

Rubber clamp cover - 24.00

Heat shrink + 15.00

Heat shrink - 15.00

Cable cutter, stripper, crimper 70.00

Vacuum system 385.00

Schematics, etc 0.00

Total 3,777.00

5% disc 188.50

Shipping 260.00

Grand total $3,848.15

All ordered!

A word about the 5% discount. I used an hour's worth of consulting services from Ken Koch (formerly of KTA). You spend a few minutes talking about what you're converting, what you want out of it and Ken will give you an estimate of performance and a suggested parts list. That cost me $75. By doing that, I saved $188 off the cost of my order from KTA.

Now if I can just get that damned engine out!

oh btw... I'm getting gauges off eBay, and I'll try cheaper alternatives for the DC/DC and Charger.. and I can get cable locally much cheaper too!

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ww321q

· #17 · Oct 1, 2008

I think they had to use shoehorns when they put the motor in my 1991 Saturn !! LOL!! J.W.

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PatricioIN

Discussion Starter · #18 · Oct 1, 2008

7

Allrighty! Well, I've had no bites at all on selling the good engine out of this donor (not even as a core to a rebuilder) so, after looking back at Gavin's vids, I've decided to just dismantle the darned thing. Hell, it'll be an interesting task for me since I've never done one, and I'm hoping it will make taking the thing out MUCH easier. I really want to leave the transmission in the car throughout this conversion!

Click on the link in my sig to see updates.. mostly just removed more and more stuff today. I'm not working on this full time - 3 or 4 hours a day on the days I can. But hey - gas tank is out for good! Also, a guy contacted me today who really wants to hang out for the project and help in any way he can. Best part, he has fabrication experience, mechanical experience and his Dad is a master welder!!

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david85

· #19 · Oct 2, 2008

There seems to be a lot of room under the floor at the mid rear of the car. Not sure what exactly your plans are, but I'm already seeing how the floor could be cut out and a battery box dropped in there.

Might want to spray some undercoating on those rust spots before wrapping everything up.

rctous

· #20 · Oct 2, 2008

leaving in the tranny may be more work later than taking it out,the alignment of the new couple and the adaptor plate is very prescision work I bolted mine together with the motor facing straight down with the tranny facing up. If you have the adaptor plate built and the coupler built from someone who has the exact dims you may luck out by leaving the tranny in all the way through it. ( but I doubt it)

Brian

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