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Old 09-16-2015, 12:30 PM   #12 (permalink)
Daox
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Join Date: Dec 2007
Location: Germantown, WI
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CM400E - '81 Honda CM400E
90 day: 51.49 mpg (US)

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Team Toyota
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90 day: 64.33 mpg (US)

Swarthy - '14 Mitsubishi Mirage DE
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A 9" dc forklift motor will be fine to propel the car at freeway speeds. Your main hurdle will be a battery pack large enough to go 200km. This is a very large battery pack. Here is a little math to show what you're going to need.

Lets estimate 350 watt hours per mile (217wh/km) which is not a super conservative number, especially if you need heat or any other power consuming accessory like A/C. Take this as a best case ball park calculation as there are other factors to account for.

At 217wh/km you're going to need 200 * 217 = 43400wh. This is a 43.4 kWh pack. That is almost double the size of the Nissan Leaf pack. So, probably one of the easiest things to do would be to find yourself two junked out Nissan Leafs and use the batteries out of them. An alternative is to use Volt battery packs. Those are ~16kWh each so you'd need three of them.

Then you have to reconfigure the pack, get a battery management system, a controller, and a charger. Then make it all fit in your Aveo. That is no small task, but it is doable.

I'm going to have go agree with what vskid said about it not being worth it monetarily. I think you're looking at at least putting $10,000 - 15,000 US dollars into this build before you're done.
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