Ben Nelson's Electro-Metro Build thread

[bennelson]

EVerytime an Ecomodder helps another, an angel gets its wings....


EDIT:
Just got two clutch hubs in the mail! Merry X-mas!

[bennelson]

I just placed an order for some new Lovejoy coupler parts.

Yesterday, I took my broken coupler bits and transmission over to Tom's house, where he and some other guys were working on his Neon conversion.

I showed them the battle damage, and what my thoughts were on the why and how it happened.

I got input from a couple of different people of ways to make my new adapter better than the old one.

Here is my basic plan for the new coupler:

Still sticking with the Lovejoy style connection, but:

Will use a larger style coupler - they can carry more torque, have more area to weld to or trim on the lathe.

Going to use the fancier spider - it can carry more torque and is less rubbery.

Going to modify the Lovejoys to have sort of a "cap" that will prevent them from sliding on the shaft farter than even with the end of the shaft. This will keep the coupler in position without using Loctite, (not strong) or set screws, which can acually throw off the centering.

I will also bench test the motor and transmission to each other and get alignment perfect, then torque the connecting bolts really well, borrow an engine hoist, have a couple friends come over, and install the motor/tranny assembly all at once into the car.

The parts should come in a few days. I should be able to work on actually making the finished couplers at the end of the week, or this weekend. Then I will have to plan a "put it in" date as soon as I can after than.

[cbergeron]

Hey Ben - I just started reading up on your mod.

I'm about to convert my Ford Aspire into an EV and I'm in the final planning stages...

I found a nice 30HP for $600 and I'm going to use a homemade speed control (manual metal contacts) until I can afford an electric speed control. I've hypermiled my car as much as I could with an ICE, so now I'm on to the next frontier: EV

Thanks for all the great info!

[MPaulHolmes]

You should make a thread! Also, is it 30 hp continuous or peak? How much does the motor weigh? $600 ain't bad! What is the 1 hour rating (how many amps for 1 hour, written on the side of the motor usually)?

[bennelson]

Originally Posted by cbergeron

I'm about to convert my Ford Aspire into an EV

Hope all my thoughts here help you. Good luck on your conversion.

Once you get going, start your own thread and post pictures! Lots of Pictures!

[TomEV]

Way back on #601 you logged 133.6 eMPG, and last month 129.92. With winter coming on, I am using the defroster which lowers the efficiency quite a bit. For November I am at about 129.58 eMPG. Looks like you could claim the #1 spot for the month if your wh/mile didn't drop like mine did!

[bennelson]

I am currently re-working the motor coupler, so the car is out of commission for now.

I think my gel batteries are more sensitive to temperature changes than flooded lead acids.

I have insulated the front batteries, but the rear ones aren't insulated yet.

Once I get it back on the road, we will find out!

[MetroMPG]

cbergeron - that's cool. Yes, please start a thread and let us know what your goals/specs are.

[Christopher Jordan]

Originally Posted by cbergeron

I'm about to convert my Ford Aspire into an EV and I'm in the final planning stages...

Charging stations have been planned from San Francisco south to several cities in Silicon Valley, but not quite over to Santa Cruz. My Aspire would not make it. Sounds like a terrific project to make one an EV but I would sure chicken out! The economy also makes me wary; since my City-el is becoming a money pit. Best of luck!!!

[bennelson]

When I was in the Los Angeles area this summer, I saw that Santa Monica has a PUBLIC EV Charging Station at the pier!



There were three "electric car only" parking spaces with inductive chargers.



Two Electric RAV4s were parked there, one charging, one just parked.



It looks like my local, municipally-owned power utility has an NEV (neighborhood electric vehicle) in the budget for next year.

Maybe I can convince them to make their charging station for it public!?