Electric car conversion: Project ForkenSwift

[MetroMPG]

Hi Len - that IS funny. Congrats on the C-Car purchase. A classic.

I don't want to chase you away, but for help with your contactor setup, have you checked in with the Yahoo C-Car group yet? Someone was describing a similar problem recently (the reverse problem, anyway) :

Quote:
Burning up reverse is a common topic. It seems like everyone's reverse melts sooner or later. - source
http://autos.groups.yahoo.com/group/C-Car/

Fairly active group, and there are some schematics and other good info available in the "files" area.

I'd try there first for getting help - that's where the expertise hangs out. I'd be really interested in hearing your car's story though. I hope you'll post more here.

[MetroMPG]

Len:

Yeah, I've been lurking around on that list too, lots of good advice. I also went to my local electric vehicle association meeting and met some local EV experts who have offered to let me rummage through their spare parts to try to fix up my contactor--on the other hand I think I may just replace the contactor with a new one.

[MetroMPG]

I also joined a "local" EV association - great resource for suggestions & assistance. Sounds like you've got it under control.

What's the story of your C-Car purchase? Barn find?

[MetroMPG]

HA! Project Forkenswift is famous

AutoblogGreen discovered the YouTube videos and posted an item:

Quote:
Don't know where these guys are located (their Web site isn't up yet) but their first two videos covering the electric conversion of Geo Metro are worth watching. The project is called ForkenSwift and the crew is using a hydraulic motor salvaged from a forklift. The first video showed a quick power-up using one battery. Now the team has added two more batteries and a controller from a 48-volt golf cart. They seem to know what they're doing and it looks like they've got a hit series out of their garage. Can't wait to see more of the conversion.
http://www.autobloggreen.com/2007/01...a-beer-budget/

[MetroMPG]

Len replies ...

I've been interested in electric cars for a few years now and every now and then I would check the EV Tradin' Post to see if there was anything in my area but there never was.

Then just before halloween there it was, a 1980 Comuta-Car only 30 miles away. I didn't even know what a Comuta-Car was when I first saw the ad, but I contacted the guy anyway. It took me two months to coordinate with him and by the time I was able to meet with the guy, I knew more about the cars than he did. He brought the car up with him from Arizona so it has been around, but there are less than 3000 miles on the odometer.

[MetroMPG]

Good story. I've only seen one C-Car in person: there used to be one parked in someone's driveway in Ottawa when I was going to school there. I walked by it regularly. I'd like to know what happened to it - nobody in the Ottawa EV association knew anything about it.

Hope you'll keep us updated with your progress.

[MetroMPG]

This afternoon I picked up 8 used 6v batteries from the forklift place. That's a bonus - the guy told me last week they were getting four in.

Did a quick test: they were all between 6 and 6.3 volts. 4 had low water (below the plates), but they guy told me to expect some would be low.

So we're going to top 'em up with distilled water and recharge them. And I guess I need to learn what's normal full voltage for 6v floodies (I'm guessing 6.35v) and how to load test them to see if there's any life left in them.

[MetroMPG]

Len cautions...

Remember not to fill them completely until after charging as the water/acid solution will expand when charging. Just put in enough to cover the plates, then charge them up.

[MetroMPG]

Thanks - I seemed to recall reading something to that effect, so that's what we did/are doing. I filled to approx halfway between the plates and the filler neck and we started charging last night.

So far so good - the ones we've charged seem to be resting around 6.4 volts (I think that's good - it's half of 12.8 !)

I'd like to do some kind of load test before putting them in the car though. Holding voltage is one thing. Delivering amps is another. I don't suppose you want to recommend a cheap/effective load test method to check for duds?

I've read 2 ideas: 1) buy a load tester; 2) just connect each battery to a load for the same amount of time (eg. the car's motor) and record the voltage sag while running, and the resting voltage after running. Duds will drop voltage more compared to the non-duds.

[MetroMPG]

Ivan just called - he bought a battery load tester. So that solves that dilemma.