Electric car conversion: Project ForkenSwift

[MetroMPG]

treb:

Have you done anything like a 0-100km/h test?

Ben:

Can it go 100kmh?

Nope - it's weak and slow.

[MetroMPG]

Inspection is tomorrow. I'm not too worried about it.

The next big hurdle is getting insurance. I've been turned down flat by 3 companies so far (won't touch a converted EV). I thought I had it sorted out: an EV owner in Toronto gave me a company name to try, but when I got in touch with them, they also said "no". On top of that, they said the other EV guy should contact them because his policy was issued in error!

On the plus side, they gave me a great rate on insurance for the Blackfly, so I switched it over to them

Another company said they "may" offer EV insurance if I send them a certified vehicle appraisal - even though I said I don't want collision/loss coverage. I'm afraid if they see $700 as the appraised value, they won't want to touch it.

[MetroMPG]

2Ton writes:

That really sucks to get hung up on insurance...

Metro, if I make my way to the big B for a few hours this long weekend is there any chance I could see the EV? A friend lives there and I may pop up from a Picton turkey fest and see him.

Sure, come on by. We'll go for a spin around the block.

But you're not confusing it with Belleville are you?? Belleville's the one that's closer to Picton, and I used to mix up the two Bville towns all the time (before I moved here).

I'm going to be out all Saturday afternoon/evening, but should be around the rest of the time. Send me a PM if you're coming and we'll work out the other details there.

[MetroMPG]

Another potential EV builder chimes in...

amazing stuff ya got here and inspired me to make my own electric car. What makes it even easier for me, ive got a neighbor who has his array of 6v trojan batteries, being amazingly old, i could still get somewhere with them.

I had a question though, have you ever thought about reconditioning the batteries, using a desulphator, or pulsing circuit? My neighbor has had his batteries for 9+ years now and some of them are still enough to be considered usable.
And have you also removed the flywheel on your transmission?

[MetroMPG]

Hi Gearshredder... glad to hear someone else is taking the plunge. Start a conversion thread!

Quote:
Originally Posted by Gearshredder
I had a question though, have you ever thought about reconditioning the batteries, using a desulphator, or pulsing circuit?

I'm not sold on the concept, and honestly not knowledgeable enough to make my own decision on whether the theory behind it is valid or not. It's come up many times on the EV discussion list, and some of the smartest people there insist that nobody has empirically shown that they make any difference.

Quote:
And have you also removed the flywheel on your transmission?

Yes, it's removed. No clutch or flywheel. Shifting via rev matching & using the synchros. It works fine once you figure it out. The drawbacks are: 1) lack of a mechanical disconnect (safety feature); 2) you can't shift as quickly as when you use a clutch.

[MetroMPG]

Well, it's official: Ontario has another registered EV!



Above: before



After!

Still not legally driveable though - continuing to search out insurance options...

[MetroMPG]

skewbe:

Very Cool!!!

Re insurance: I don't know that they would specifically ask you if you gutted it and put in a electric motor and batteries, might be a canada thing. In the states you would just say "I have a 98 metro, vin ..., I want liability only, here's my money". You might have some issues if there is an accident, but it will get you to legal status anyway.

Yeah, I was considering just not telling them (or lying), but the potential consequences and the thought of dealing with the ins. co. in that situation isn't very appealing. It would be a last case option.


2ton:

What about companies that specialize in motorcycle insurance? They might know who you could call.

http://www.kingsway-general.com/KGWeb/

Thanks. I called a Kingsway broker today and gave them the info - still waiting to hear back. Interestingly, 1) they didn't seem fazed by the request, and, 2) they didn't specifically ask who did the conversion - first company not to specifically ask that. As a specialty vehicle insurer, they probably just assume I did it.

BTW - nice to meet you and your son on the weekend. Hope you had an efficient drive home, and had somewhat more than 9.1 peak kW (12 hp) on tap! (that's 190 amps @ 48v nominal - is that what we saw? I should have written it down.)

Quote:
Originally Posted by Gearshredder
the small stuff, i.e climate control

Climate control, schmimate control! Don't need it on my bicycle, so I won't miss it in the car. I'm sure I'll get by for 9 or 10 months of the year just fine. And when (if?) it's -20c it won't have any range anyway, so I won't want to use it!

[MetroMPG]

hey, the climate control was just an example

Yeah, I know. There are still a pile of things that need doing.

But other than a controller bypass experiment (full POWAH!), and I suppose the clutch activated emergency disconnect (maybe I should do that before the bypass ), I'm taking a break from working on it.

[MetroMPG]

Originally Posted by 2ton

It was a fun ride/drive! My son was very impressed. I forgot to tell my better half that he wasn't in a booster seat and was in an uninsured vehicle as we hit 195+ going uphill! hehe

I noticed 200 or a needle width less on the first ascent and it did hit 195+ when we looped around to confirm that. Close enough...

Thanks!

Not a problem. 195+ uphill - that's funny.

Let's call it 195 amps then. Benchmarked!

I've since done a bit of reading on the Citi/ComutaCar Yahoo group and the opinion there is that a 48v Curtis 225A controller such the ForkenSwift's *will* result in both slower accel and a lower top speed than those cars' original contactor controller. Bodes well for a controller bypass experiment. MORE AMPS!

And, it looks like the Kingsway broker has found us an insurer (though not Kingsway, ironically). Fingers crossed, I'll know for sure tomorrow.

[MetroMPG]

Snax starts to see the low voltage light...

I am increasingly starting to believe that a lower voltage system is going to be the way to go with my conversion. Although I don't want to fart around with a mess of used parts, just limiting the system to 72 volts cuts costs dramatically. I figure the entire conversion including adapters and accessory electronics could all be done for $2500-$3000 using all new parts. And that would provide a top speed of around 40-45 in my MR2 (which is all I need).

Hunting up a used motor and other accessories could cut that by half or more.