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Old 08-16-2008, 03:13 PM   #6 (permalink)
MPaulHolmes
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Join Date: Feb 2008
Location: Maricopa, AZ (sort of. Actually outside of town)
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Michael's Electric Beetle - '71 Volkswagen Superbeetle 500000
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Dr. Larry EV

Hello! Here's my 2 cents:

First, I recommend getting a car with a manual transmission. Automatics can be done, but the range is less. For a good example of this, check out "n2confusion" on YouTube. He's very helpful too, if you have any questions.

First, check Ebay every now and then for at least a 72v 400 amp controller. They come along every now and then. There was a guy selling a bunch of them. He had 17 as of a couple days ago, and then out of nowhere someone bought all 17! I was just about to buy a couple extra myself! OOOH that made me so mad.

For a good example of how to do a small car for around $3000-$3500, go to google and type:

Dr. Larry EV

The car I'm doing could have had 40 mile range, but I only needed like 10 - 20 mile range, so I got fewer batteries. (also the back end of my car was rusted out, so I didn't want too much weight)

Here's a cost breakdown for a smallish EV with approx. 40 mile range and a top speed of about 55 mph (but 40 mile range only at like 35 mph):

DC Motor: $300-$800
72v Curtis or Alltrax Controller: $300 - $750
Contactor: $95-$200 (to turn on the power with the key)
2 gauge cable: $40-$140 (to connect the batteries)
lugs: $50 (to connect the cable to the batteries)
Adapter plate / Coupler: $80 - $500 (to mount motor to transmission)
Angle Iron for battery racks: $20 - $60
Batteries: $1150 (13 Deep Cycle Walmart 125 Amp*hr batteries)
Pre-Charge Resistor: $5
300 amp ANL Fuse & Fuse Holder: $15
PB-6 Throttle: $75
Charger: $140 - $450
Extension cord: $15-$50
Emergency disconnect: $30
Welding fees: $0 - $300

That's about it. The low end price means you can either do it yourself or you have a very good chance of buying something from Ebay or some other creative source at that price. Also, the 125 Amp*hr Walmart batteries have an 18 month replacement warranty, so that's nice. Dr. Larry got several years of use out of his Walmart batteries.

So, the low end total is about: $2400 or so.
The upper end is more, but my baby is waking up and I can't add it now! oh no!
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Last edited by MPaulHolmes; 08-16-2008 at 04:01 PM..
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