Ben Nelson's Electro-Metro Build thread

[bennelson]

That guy is asking $1200 for the Miata.

I guess right now I am really leaning towards the simpler/lighter/cheaper the better.

Miata might make a better second EV conversion for me.

[MPaulHolmes]

Originally Posted by bennelson

You are right on with 72 volts.

Controller costs seem to jump up above 48 and above 72 volts.

72 volts seems like a reasonable way to go.

There is a Kelly controller that is quite a bit cheaper than alltrax and Curtis (and Zilla, and etc...) that goes up to 84 volts. Their 72v 400amp controller is $389 NEW from their site. I didn't find the 84 volt one there today, which I have been eyeing, but they said they still carry it.

[MPaulHolmes]

Originally Posted by bennelson

PS: Darin is stalking me on other forums

Then quit doing such dang awesome cheap EV conversions using a forklift! You know he won't be able to resist reading about such a project.

[Daox]

Just curious as I've only browsed through a few things on EVs. How hard/expensive is it to find a controller with regenerative braking capabilities?

[MPaulHolmes]

Originally Posted by Daox

Just curious as I've only browsed through a few things on EVs. How hard/expensive is it to find a controller with regenerative braking capabilities?

Here is a Kelly Controller price list:
KD72201,200A,PM with Regen Kelly $ 319,
KD72301,300A,PM with Regen Kelly $ 369,
KD72401,400A,PM with Regen Kelly $ 439,
KD72501,500A,PM with Regen Kelly $ 519,
KD72601,600A,PM with Regen Kelly $ 599,

Each of the controllers are programmable from 24v to 72v.

I don't think regenerative braking works very well with DC series wound motors, but I don't have any first hand info on that.

[bennelson]

From what I have heard, nobody has much experience yet with the Kelly controllers. They do look to be reasonably priced AND offer regen.

Series Wound DC motors aren't ideal for use as a generator. Some of the other styles of motors work well though.

Mr. Sharkey's Electric Rabbit uses a shunt-wound motor and features regenerative breaking.

I have heard that permanent magnet DC motors also work well for generation.

Regenerative braking is NOT high on my list of priorities. As this will be my first electric car conversion, I am looking for cheap/easy/uncomplicated.

Now if I can end up easily adding regen brakes, I definately would.

[MetroMPG]

Here's a conversion using a 72v Kelly:

http://galaxy22.dyndns.org/ev-talon/

[bennelson]

Feb 6th.

It's the middle of a blizzard here. My wife is home from work because of it. Also she has the sniffles & cough.

I am going to try to remove the wheel drive motor from the forklift today.

We'll see how long it takes my hands to go numb.

[bennelson]

I wasn't able to figure out how to get the drive motor off.

First, I had to disconnect a weird drum brake to get at anything else. Then I removed all the bolts that looked like they were holding the motor on. I put a nut on the end of the drive shaft and carefully tapped on it a little. Not sure what else is holding it in place other than a gasket connecting it to the block it is attached to.

After all that, I decided to remove the big pump motor. It wasn't nearly so difficult, bolt one bolt was nearly inaccessable. It took about half an hour of turning the bolt a tiny bit, sliding the wrench off, flipping it over, wrench a little more, flip it over, repeat....

The big pump motor weighs around 120 lbs, as best I can tell, I had to balance it funny on the scale to weigh it.

The outside measurements are 9" diameter and 12" length

Still, this one doesn't have a real drive shaft either.

[bennelson]

I just talked on the phone to a guy in the Raymond (fork lift brand) parts department.

The motor has an ID plate on it, so I just gave him the part number and asked what it would cost for a new one.

Guess how much?




$2283.95!