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Planning Ford Ka 1999 conversion

7192 Views 3 Replies 2 Participants Last post by  YohnnyLuksh
Hello!

I am a geologist from Latvia (Eastern Europe) :) and newbie to EVs and this forum!
Unfortunately in my country EV is still something out of science fiction... But I have been quite close to green technologies for several years and finally decided to give it a try!

I am new to EVs, but read quite a bit of info on internet and also e-books. I also have some mechanical experience with drilling rig & truck repairs. I already made some calculations @ http://www.evconvert.com/tools/evcalc/ and Seth's Leithman's book.

So planned things:
Ford Ka 1999
Range recommended up to 60 miles
Speed up to 60-70 mph
Planned budget for now is about 8000$

Curb weight before conversion ~1800 lbs, w/o ICE parts I expect 1300 lbs hopefully :). After conversion curb weight expected ~ 2500 lbs (yeah, because of lead-acids...)

Power required 15,6kW @ 60 Mph, 22kW @ 70 Mph on flat ground, calculated from aero drag + rolling resistance (there are no hills here)
Now I'am considering DC 144V system, but also interested AC (because of efficiency & regen). I know, forum is full with AC vs DC things, but for me $$$ could be an issue.

So what do you think about such setup:
ADC FB1-4001A, 9.1" 144V DC motor
Curtis 1231C controller
And... unfortunately :D 12 x Trojan T-1275 12V 150 Ah = 18kW batteries at beginning. If I could gather more $, then LiFePO4 ~45 x 3,2V x 160Ah = ~23 kW.

Or better try to aim @ high voltage & lower amps & AC system?
Would Trojans bring really these 18kW to motor? I am watching that lead acids are quite critisised @ forum!
Maybe there is someone from Eastern Europe to show his vehicle and share some experience? Also parts getting could be a problem. I was shocked when I found that Impulse9 costs around 4000$ @ Sweden!!!
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Unfortunately in my country EV is still something out of science fiction...
I've always thought eastern Europe was a hive of interesting niche technologies...?

Maybe there is someone from Eastern Europe to show his vehicle and share some experience?
CroDriver comes to mind, but still not 'quite' in your neck of the woods.
I've always thought eastern Europe was a hive of interesting niche technologies...?
Well, there are some scientific work in various fields, but
and I am struggling to find any EV here. I found out that at least one conversion some time a go there was made on car ZAZ :) , but I cannot locate it anymore!
I am starting to consider LiFePO4 pack, and maybe to aim for higher voltage AC system.
320V battery pack, consisting of 100 x 3,2V TS 60 Ah gives 19,2 kW.
Price is 3x times 144V lead-acid pack price, however, I hope cycle life & efficiency will pay. Also winter is pretty chilly (up to -30 C) here.

Maybe you have some recomendations about AC systems? Inverter, controller, motor? For ~20 kW continuous power for small car (like Ford Ka)?
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