(Photo: Egan Snow)

For a while now I’ve been mulling over a blog post featuring top online resources about EV conversions: sites that educate, facilitate and inspire.

I already had a short list of what I wanted to point to, but instead of wracking my brain to flesh it out, through chance I found myself mulling over nearly the same list I had in mind over at Nikki Bloomfield’s blog, aminorjourney.com.  (Nikki has plenty of EV experience: she owned and upgraded a City El, and has modified her Toyota Prius to plug-in operation.)

You will of course arrive at link #7 of Nikki’s list and may think, perhaps cynically, “well of course EcoModder would like this list.  It’s ON it!” (We’re recommended specifically for info about efficient driving techniques and aeromods.)

While it is generally true that flattery will get you everywhere, you’ll just have to believe me when I say finding EcoModder there was nothing more than an unexpected bonus (though entirely deserved, it can be argued).

Head on over to aminorjourney’s Ten Top DIY EV conversion links and read Nikki’s reasoning behind each of her selections:

1. www.evalbum.com
2. The EVDL
3. www.KiwiEV.com
4. DIYElectriccar.com
5. EVconvert.com
6. EVCapri.com
7. Ecomodder.com
8. EVparts.com
9. Project Forkenswift
10. WhiteZombie, Blue meanie and Plasmaboy

What do you think?  Are there any must-see or must-read conversion resources that are missing?  Let us know in the comments.

UPDATE: Just found this great link on electric car conversion issues.

The 2009 New York International Auto Show was a mixed bag for green car enthusiasts. On the one hand, there were some exciting small cars on display; on the other were a whole bunch of new SUVs. Here are our posts in no particular order:

• 2011 Ford Fiesta: An Unexpectedly Impressive Car

• 2010 Ford Fusion Hybrid: Built for Ecodriving

• Fisker Karma: Even More Impressive in Real Life

• One Global Emissions and Efficiency Regulation to Rule Them All

• Kammback Creator to be Inducted into Automotive Hall of Fame

• Automakers Getting Back Into the Sub-prime Loan Business?

• Chrysler Showcases Electric ENVI Concepts

• Ford Highlights Fuel Economy with Interactive Display

• The SUV Strikes Back

• Mazda2 Officially Coming to Canada

• VW Golf Wins World Car of the Year Award

• Breaking News: Mitsubishi Announces the i MiEV will be Sold to the US Public

• Fiat 500 Wins World Car Design of the Year Awards

• Honda FCX Clarity Wins World Green Car of the Year Awards

• GM and Segway’s New PUMA Project in Action

• Chrysler Stuns with Fiat 500 Drive Out

• Scion Announces iQ Concept

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Parting thoughts…

Naysayers are quick to scoff at medium-speed electric vehicles as “useless”, arguing that they’re too slow and don’t go far enough on a charge (OK, they say that part about almost all EV’s).  What these people fail to understand is that their vehicle needs are not the same as everyone else’s vehicle needs.

Tens of thousands of people in North America and elsewhere have already bought and are using low- and medium-speed electric vehicles for local driving, from actual golf carts, to NEV’s (neighbourhood electric vehicles), to faster cars such as the classic Citicar/Commutacar, to the newer Zap Xebra.

And now they’re building their own, on the cheap!

Feel motivated?  Well then, here’s what we learned about budget EVs from the 3 amigos, both in general and specifically:

In general…

Be realistic

Understand that you probably can’t build a highway capable EV with a 40+ mile range on the cheap.  (But if you’ve done it, drop us a line!)  Each of these cars tops out around 45 mph, and a more realistic “working” top speed is probably low to mid 30′s.  Steep hills are to be avoided.

No experience required

- two of the builders had zero experience with electric vehicles
- one had little experience working on cars in general
- all you need to know you can learn on the Web

Reuse & recycle

Read the build threads for these vehicles and you’ll discover lots of creative low-cost recycling ideas.  “Repurposed” parts in the ForkenSwift, for example, include bits from a dead inkjet printer, old tricycle, dead 12v cooler, old bed frame, used welding cable and more.

Patience is a virtue

The challenge of buying used parts and scouring eBay for killer deals is that it will probably take some time to find the things you’ll need.  If you’re an impulsive type prone to temper tantrums when you can’t get something you want RIGHT NOW, a budget EV project is probably not for you.

Let no parts go to waste

Just because you’ve decided the internal combustion engine is useless for your purposes, doesn’t mean it’s actually worthless.  In the case of both Metro projects, slightly more money was recovered by selling good parts (fuel tanks, radiators, working engines) than the cars originally cost!  As well, hundreds of dollars were recovered by selling the forklift chassis after stripping the electric parts.

More specifically …

Go light

By definition, a medium speed budget EV is not going to need to carry a lot of batteries or generate a lot of power.  Which means you should try to find a lightweight host car to keep the overall power to weight ratio manageable.

Forklifts and golf carts and used parts, oh my

The biggest fleets of EV’s in the world are found in warehouses and on golf courses.  The companies that sell/service/repair these vehicles are potentially a good source of affordable used parts, particularly if you take an entire old unit off their hands.

The 72 volt threshold

The lower your system voltage, the lower your component and battery costs.  That said, a 48 volt 400 amp subcompact car is just barely workable in what most people would consider normal driving, and only on flat roads.  A 72 volt setup is more realistic, and as it turns out, motor controllers that can handle 72 volts seem to be just below a threshold where the price goes up significantly.

A 48-72 volt battery pack (assuming lead-acid) also keeps you closer to the weight limit that a smaller host vehicle can carry without exceeding its gross vehicle weight limit (affecting suspension & braking ability).

Used batteries

Second hand batteries can be a viable option, which is good because along with the motor and motor controller, the battery pack is one of the 3 costliest parts of an electric conversion.  Depending on your range needs, it is possible to find used ones that may meet your minimum range goals.  Two of the three cheap EV’s featured in this series are running on batteries from other EV’s owners which were either upgraded, or replaced once they no longer met their minimum range needs.

Connect with experts & people with experience

Electric Vehicle Discussion List – evdl.org
EValbum – evalbum.com
EcoModder Fossil Fuel Free forum – ecomodder.com/forum/fossil-fuel-free.html
DIY Electric Car forum – diyelectriccar.com

Well – what are you waiting for?

]]> http://ecomodder.com/blog/dirt-cheap-diy-electric-cars-part-5/feed/ 3 http://ecomodder.com/blog/cheap-diy-electric-car/ http://ecomodder.com/blog/cheap-diy-electric-car/#comments Tue, 02 Dec 2008 14:32:53 +0000 Benjamin Jones http://ecomodder.com/blog/?p=623

So you want a 100% electric car for commuting or running errands in your town or small city.

Maybe you’ve dreamt of whipsering down the road in a clean, quiet Tesla roadster … and then you woke up screaming at the thought of the $109,000 U.S. price tag.

In that case,  may we present the other end of the EV spectrum: a trio of street legal electric cars converted from gasoline to battery power for an average price of $1450 each.  (No, that’s not a typo.)

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We have written previously about Project ForkenSwift, the electric Geo Metro made from forklift and golf cart parts for the princely sum of $672 (its build cost has since crept up to  $955 – details in part 3).  At that time, it might have been easy to dismiss that low-cost grocery getter as an unrealistic one-off, assembled by obsessively cost-conscious builders.

But since then, two more affordable, electric runabouts (their motors also sourced from used forklifts) have hit the streets.  Which lends proof to the idea that electric drive does not have to be prohibitively expensive for the motivated tinkerer (note that we specifically didn’t say “experienced” or “skilled” tinkerer).

To be clear, nobody is pretending for a moment that these cars can go even remotely as fast or as far as a Tesla.  But compare on “cost per range” or “cost per MPH”, and they’ve got the roadster beat!

(Tesla image: Tinou Bao)

OK, OK, so the average motorist won’t be lusting after these cars for their range & performance specs (or their looks, for that matter).   They probably wouldn’t even meet the current daily needs of the motoring majority.  But that doesn’t mean “medium speed”, relatively short-range EV’s can’t be practical for some drivers.   Used in the context they were designed for, the owners of these cars each report that they are useful and fun vehicles.

In this 5 part series, we’ll find out how they did it, what lessons they learned along the way, and what advice they have for others thinking about inexpensive EV conversions.

Next, the three EV amigos:

Part 2: Ben Nelson’s 1995 Geo Metro “Electro-Metro”

Total build cost, including car: $ 1200.00
72 volts / 400 amps
Wisconsin, USA

Part 3 – Darin Cosgrove’s 1992 Geo Metro “Project ForkenSwift”

Total build cost, including car: $ 955
48 volts / 400 amps
Brockville, Ontario, Canada

Part 4 – Paul Holmes’ 1973 VW Beetle

Lacey, Washington, USA
72 volts / 300 amps
Total build cost, including car: $ 2100

Part 5 – Parting thoughts

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The merger is officially off, so it seems like if any of the major manufacturers are going anywhere anytime soon it will be in a less pleasant way that a corporate restructuring. So, let’s hope that doesn’t happen. Anyway, here’s some of the most interesting stuff that’s been floating around the internets this week:

• GM Asks for Bailout Money: Since the marger isn’t going through, GM needs to ask for money from the government. Looks like they’ll probably get some, too.
• 9 Tips to Winterize Your Car: This year you’ve got to do it EcoModder-style or not at all!
• Crowd-sourced Interview with ZAP!: A good interview put together by the community with some interesting answers. Worth checking out if you haven’t already.
• Roadside Assistance for Cyclists: I’ve only every needed this once because I ride prepared for the worst, but I can see how it would be a smart service to have.

Thanks for tuning in! I’ll have more for you next week.

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Well, for once it seems like there isn’t much news about the possible GM-Chrysler merger, even though the two companies expressed interest to finalize the deal before the upcoming election (don’t forget to vote, US citizens!)

• Audi aids ecodrivers with new HUD: Who doesn’t hate stopping for traffic lights? If Audi has their way, that might become a little less necessary.
• Japan to get MagLev trains by 2025: MagLev trains have been interesting people for a few years now, but their expense has kept them from impacting rail in a major way. That might be changing in Japan.
• Ford’s encouraging ecodriving too!: Ford’s new Smart Gauge may not be as innovative, but it’s an important step for the automaker.
• Courts block NYC hybrid taxi plan: Mayor Blooberg may be getting a shot at additional terms in office, but he won’t be getting his hybrid taxi legislation.

Thanks for tuning in! I’ll have more for you next week.

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Last week, the news was all about a possible GM-Chrysler merger. That doesn’t seem to have gone anywhere fast, but there have been talks about Ford selling off some of its share in Mazda.

• Ford Selling 20% Share in Mazda: Will Ford go through with it? Will anyone want to buy? This is kind of surprising since I always felt Mazda was one of the stronger points in Ford’s general engine design.
• Driving Less? Don’t Forget the Maintenance!: ABG reminds us that even if we’re driving less, we still need to check things like our tire inflation regularly. Which reminds me…I need to change my oil!
• Electric MINI Will Debut at LA Auto Show: Are you excited? I know I am.
• Oil Prices Plunge Below $70: Be it a good or a bad thing, it definitely reflects how volatile the world petroleum markets have been this year.
• DIY, 100 mpg Car Back on the Road: Who can pass up a great, DIY car that not only looks great but gets 100 mpg in the real world?

Thanks for tuning in! I’ll have more for you next week.

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If you’re not still reeling from the plummet that the world markets have taken this week, you might remember that last time around I said that Chrysler had stolen the show with its surprise EV unveiling. Well, it’s both Chrysler and GM’s turn again this week! Be sure to read the first story, if you read anything!

• GM and Chrysler Talk Merger: Sources say it’s only a 50-50 shot at this point, but if it happens, it would certainly be monumental. Big Two just doesn’t have the same ring that Big Three has, does it?
• Bailout Plan Gives Tax Break to Bicycle Commuters: The bailout, laden with pork as it is has become the talk of the town, recently, and some of you may be excited to know that it includes a tax break for cyclists.
• Small Cars Are Bad for the Environment?: Some industry mouthpiece wants us to believe that small cars are bad for the environment, but I show you in this article why that’s just a ridiculous claim.
• Toyota iQ Coming to the US?: For a while I’ve wanted Toyota to flipflop and bring its new, small car to the US, and recent rumors suggest it might be doing so under the Scion badge.
• Beijing Raises the Price of Gas: During the Olympics Beijing did a whole host of things in order to keep cars out of the city, and I think this price increase is a continuation of what they saw working there to cut congestion and pollution.

Thanks for tuning in! I’ll have more for you next week.

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Chrysler really stole the show this week, by stating that they haven’t been completely idle and that they are, in fact, developing some exciting electric cars for the next generation of automobiles in the US. However, there’s been a lot more excitement in the news, though for most of us, it’s probably been overshadowed by the current financial crisis. Anyway, I’m here to get you up to date!

• GM cancels plans for overtime Cobalt production: GM was hoping to ramp up Cobalt production on the weekends to get out more units of its flagship small, efficient car, but it seems like it just doesn’t have enough parts to make the plan a reality.
• As economy implodes, the bike industry booms: First the gas crisis, and now the financial crisis…But biking looks more attractive than ever!
• Video: Chrysler’s new EVs in action: Ready to seem them go? I kind of feel bad for Chevy with Chrysler stealing their wind right after the official unveiling.
• PLX Devices Kiwi Review: Luckily, EcoModder got a little hands on with the PLX Kiwi recently, and Tim was able to give the little device a good review from an ecomodder’s perspective.
• No More Excuses to Not Wear a Helmet: As long as we’re already talking about cycling as a transportation method, it would be prudent to make sure you wear your helmet!

Thanks for tuning in! I’ll have more for you next week.

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More great news in the lead up to Paris as well at 2009 models and general change that’s in the air.

• Hybrid cherry pickers tested in AZ: The great thing about fleets is that it’s a little easier to crunch the numbers on fuel usage and cost, and fleet conversions improve the vehicles which are in use the most.
• Honda and Yamaha to Sell Electric Motorcycles: Big news from two of the world’s biggest motorcycles manufacturers. They won’t be high powered, but they will have good range and will probably be big hits in the Japanese delivery fleets.
• More bikers mean safer biking: This is one cycle that’s good for everyone.
• Interview with Auto Alliance’s Charles Territo on EcoDrivingUSA: I got the wonderful opportunity to do an interview with Charles recently. Here’s what I learned.
• China’s taking to destroying motorcycles to prevent crime: It sure would be harm to break (or follow) the law on a motorcycle if the Chinese government smashes it.

Thanks for tuning in! I’ll have more for you next week.

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Another week, another weekend, and some really exciting news. Personally, I think a lot of the goings on looks pretty neat, but I guess that’s what we can expect with the lead up to auto shows and the 2009 model year!

• Honda Wants to ‘Change Customer Perception of Hybrids’: Neat post from WIRED Autopia about Honda’s approach the the hybrid market.

• Honda Insight Concept to Debut at Paris Int. Auto Show: My post announcing the new Honda Insight Concept, complete with real, official picture straight from Honda.
• 4 Ways to Add a Gas Mileage Display to Any Car: A good guide to the available options for anyone interested in getting a little more in depth with their ecodriving.

• Lutz: “Tear Down This Wall!”: Lutz it calling for the US to step in line with the rest of the world on crash testing after it was the Big Three that caused the current US isolation in the first place.

• Boston Taxi Fleet to Be All Hybrid by 2015: That’s right! Taxis and other city vehicles get hit really hard fuel economy-wise, so they’re one of the best things to replace with hybrid vehicles.

Thanks for tuning in! I’ll have more for you next week.

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One of the saddest things about blogging is that there’s never time to talk about everything you want to. It’s a good thing, then, that there are lots of other people out there talking about things, too. I’ve decided to complement the Sunday Forum Roundup by doing a net-wide roundup on Saturdays for you casual weekend browsers. Every week I will be sharing my favorite stories from EcoModder and beyond. If you have any more suggestion, post them in the comments!

• How much power do EVs really use?: A great post from the Telsa Founders Blog about how much energy it really takes to power an EV.
• Shai Agassi’s plan to put electric cars on the road: Wired talks to the man himself to put together this very in-depth, well-written article.
• Ford Tests Improve Gas Mileage 24% with EcoDriving: My very own post about Ford’s foray into ecodriving.
• RideTheCity.com: A Google Maps App for Safe Biking: Some neat stuff from TechCrunch about finding safe routes for all you bike commuters out there.
• Toyota iQ: The Smallest Four-Passenger Car in the World: Treehugger brings us the word on one of the most exciting cars to not hit the US market in a long time.

Thanks for tuning in! I’ll have more for you next week.

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