[PatricioIN]

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

 

[PatricioIN]

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.

 

[PatricioIN]

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.

 

[PatricioIN]

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.

 

[PatricioIN]

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..

 

[PatricioIN]

Taking an engine out is the easy part.....


Ben

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

 

[PatricioIN]

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.

 

[PatricioIN]

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!

 

[PatricioIN]

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!!

 

[PatricioIN]

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.

yeah, I plan on doing something with the rust.. it's odd that it's so rusts free except for a couple of pieces (they must be made of a different type of steel or something)

I thought about boxes below the rear seat, but I really want to keep the seating in tact and there is only about 8 inches or so of space.. not as much as it seems.

 

[PatricioIN]

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

I'm keeping my fingers crossed.

Which makes it damned hard to work frankly.

 

[PatricioIN]

This is a pretty good explanation of one of the more common methods:
http://ca.youtube.com/watch?v=DrE2jRghyO8&feature=related

that's sort of what I had in mind.. who is this coming from, do you know?? I wonder how much they charge for the setup they're talking about...

 

[PatricioIN]

What are you doing for the adaptor plate and coupler? Local fab?

Personally that part scares me a tad. I plan on buying them prefabbed for my gearbox and matched to my motor.

I think I will end up buying a welder and building my own battery boxes. I looked around a little, and decent welders are cheaper than I thought.

You said you're going with a 120V system. I'm curious about how you came to that. I hope to squeeze 144V in my Saturn, but I don't want to sacrifice amp hours to do it.

...and I must ask... Did you wash the ZX2 with Irish Spring? 'cause it looks smooth as a baby's arse!

I'm a man of many talents!

..the main reason I chose 120 v is simplicity... same voltage of my outlets.. Seems if you go over 120 everything gets more expensive. Plus I know a guy who has done many conversions and he does them all at 120. I've been in one of his coversions and it is plenty fast enough, with enough range, etc.

I did pay Ken of EV Consulting to do a quick analysis of my wants/needs and he verified that my 120v sys (and all related components) should work fine for my needs.. highway speeds when needed.. ~50 mile range, adequate acceleration. I just need it to be quick enough to keep up decently with traffic.. I have a prius, so I am no hotrodder.! (I save that for road rallies in my Miata!)

 

[PatricioIN]

If you read the more information about that video it looks like its coming from evamerica. That looks like a great way to do the adapter, and after seeing that, i may go that way wity my mx-3 conversion. Looking through the EVA catalog it looks like that adapter plate will run about 700$

hmm.. surely I could have it made locally for less.. I finally decided the engine and tranny are coming out.. Just have the motor mounts left to unleash the beast! Taking the driveshafts out wasn't the newbie nightmare I had envisioned. Of course, I may say different trying to reinstall it all. lol!

Removed the exhaust, all fuel line, emission line, heat shields (there were four or five of 'em!) and got the driveshafts off and shift linkage undone.. All in all, a long day but some good progress!

 

[PatricioIN]

...and out she came!!!

 

[PatricioIN]

Thats one big chunk of metal! Did you buy or rent a lift? Was it really as bad as you thought it would be?


Ben

nah.. once I decided to go ahead and take the eng and tranny together like advised, it was just unbolting, unbolting, prying, etc.. The actual removal was very quick and easy. Life is so much simpler with the proper tools! Rented the engine hoist for 4hrs (min.) for less than $30... took longer to go get it and return it than the amount of time I actually used it. God love my Prius.. it's amazing what you can fit in that thing!

 

[PatricioIN]

Nice work. Looks like we may be racing, i just pulled the smallest production v6 ever made out of my mazda MX-3 on satuday. My engine compartment looks quite similar to yours now. Now i just need to remove the fuel tank, lines, and the engine wiring harness.

-Derek

yup, all that is out on mine already.. 'cept for the engine wiring.. just got my wiring diagrams in the mail today!

edit: btw, most of what is coming out of the car is out (maybe a couple of very small things left) and I've removed 560lbs of weight! Better than I had hoped.

 

[PatricioIN]

Removed clutch, clutch assembly, flywheel - measured magic # (though I won't be using clutch). Cleaned tranny inside/out... coming along. I believe my motor at least is on the way, so I want to be ready for it.

 

[PatricioIN]

What you planning on going with for batteries? AGM? flooded lead acid? I am curious about the total cost of this once it's closer to being finished

: : off topic : : Please post pictures of this conversion. I also have an mx-3 that's had a lot of work done it it and was thinking about doing a conversion on mine.

Click on the link in my sig line for the website of the conversion. There are also lots of pics and info in the garage section here.

Batts will be 15 Interstate flooded 8v(U8VGC), 170 Ah capacity @ 20hrs. Total weight 975lbs.. quoted price $1500.00
http://www.interstatebatteries.com/content/product_info/golf_f.asp?js=1

I am trying to keep my conversion budget at $7,500.00. It'll be tight to stay on budget.

 

[PatricioIN]

...cleaned up the motor compartment today. Nothing too exciting, but had to be done. UPS seems to have a 127lb package scheduled to be delivered to me tomorrow.. my motor?!?