David's 1996 Civic LX EV

[TheSGC]

On Friday I removed all my batteries to check them out and start installing my Farman battery heater pads. I used my equalizer to fully charge each battery, and do a little equalization on them. I got them to about all the same voltage, which was real nice to see.

I was hoping to get the pads installed today, but was distracted and haven't gotten around to testing the pads in the basement. I had to build my own temperature control circuit and I tested it out on a light bulb, now I need to test it on the pads. What is does it turn the pads on until they reach 75F, then shut off until they reach 69F and turn on again.

Tomorrow is looking like another snow day, so I might actually get time to finish the circuit that controls the cabin heat. I have it planned out, but needs to build the board then write the software for it.

[MetroMPG]

Will you be posting details of your heating control circuit(s)?

It has been slightly warmer (OK, less cold.. around -5C to 0C) here over the last week, and the ForkenSwift feels almost sprightly again! Happy batteries and much less rolling resistance will do wonders...

One year maybe I'll get around to insulating those poor floodies...

[TheSGC]

Originally Posted by MetroMPG

Will you be posting details of your heating control circuit(s)?

It has been slightly warmer (OK, less cold.. around -5C to 0C) here over the last week, and the ForkenSwift feels almost sprightly again! Happy batteries and much less rolling resistance will do wonders...

One year maybe I'll get around to insulating those poor floodies...

Yep I will post them once I get a better drawing of them. I have to find part numbers and stuff because I did not buy any of control circuit parts, I have been hitting the supply room at school and the electronic salvage yard.

Insulation alone only keeps the heat in for so long with my EV. The heater pads should do wonders on keeping these guys above 70F.

I can't wait to get nice warm weather and have lower rolling resistance! I have already calculated a 19% improvement in performance when I changed to a Zilla and upgraded the suspension, and that was in 35F weather!

[TheSGC]

I finished installing the pads and left them on overnight and WOW! Here is the link to my website: Civic Electric Car Conversion: Heater Pad Installation

Last night it was 35F out and my batteries were at 50F because they had just come in from the basement. I left the pads on all night, and they brought the batteries up to 78F! The pack was re insulated really well so the pads just had to kick on every so often once it got it up to temperature. My drives today was AMAZING! It was the first time I got to drive the EV with full potential using my Zilla, and it was great!

I ran once this morning, and the voltage sag was low, and comparable to summer time weather! That was a 4.8 mile run, then I charged up the EV and this afternoon I took it to my arch enemy, a set of hills about 3 miles from my house that my EV would crawl up at walking speeds with the Kelly. I was doing over 30 MPH over them!! My EV grin/ EVil EV laugh were full on today!

Now I just need cabin heat and I am back to full time EVing!

[TheSGC]

I have been busy working breaking in my batteries slowly, for optimum life. I now have over 210 miles since I installed my Zilla, and I am putting more on daily. I can now safely drive 13 miles, and I am slowly increasing it. I want to have a few good drives at 17 miles before I take it back to school, and spring breaks starts soon so I should have plenty of time to drive it.

The weather has already started to improve, so I may not need cabin heat, but the batteries still need it.

[MetroMPG]

We've had a few warm days here, too. The ForkenSwift's range & efficiency is slowly crawling out of the basement.

ALSO! Since about mid-Feb, the sun actually warms up the inside of the car quite nicely.

Originally Posted by TheSGC

I have already calculated a 19% improvement in performance when I changed to a Zilla and upgraded the suspension, and that was in 35F weather!

I wonder how much of the improvement can be attributed to the Zilla. I don't know much about the inner workings of controllers, but I'd be surprised that there could even be a 19% difference between two different types of mosfet based PWM controllers. (I'm assuming they're both mosfet based.)

[TheSGC]

Originally Posted by MetroMPG

We've had a few warm days here, too. The ForkenSwift's range & efficiency is slowly crawling out of the basement.

ALSO! Since about mid-Feb, the sun actually warms up the inside of the car quite nicely.

I wonder how much of the improvement can be attributed to the Zilla. I don't know much about the inner workings of controllers, but I'd be surprised that there could even be a 19% difference between two different types of mosfet based PWM controllers. (I'm assuming they're both mosfet based.)

The Zilla is IGBT based vs MOSFETS of most other controllers. I think most of my efficiency came from an aligned rear end and the fact that the Zilla can produce the AMPs I need at lower RPMS to maintain speeds on inclines.

I have a lot of battery care to work on this week, but I am hopeful everything will be all set for commuting again.

I also have a bin that I am using to save up for a new set of batteries because I am a feeling the current set won't last more than a few months at the rate I use them at. I have AGMs on my mind.

[TheSGC]

I am now looking into a new battery pack, with larger capacity. Right now I get about 12-13 miles of hilly driving, but two batteries have weakened to the point where they drop so low I am risking them reversing. I have about 1500 miles on the pack and it is meeting all my around town needs, but this EV MUST be a full commuter within two months, so instead of messing around with my current setup I will suck it up and get a pack that will work.

Basically, my Zilla alows me to zip around and maintain speeds with ease, but the batteries do not like it.

I am looking into 8VGC batteries, that should give me a solid 20 miles, probably more like 27 miles of range at 35-40 MPH. I have to design and build a new battery rack, so finding a way to weld it will be a problem. I am leaning towards US Battery 8VGC, and supposedly Sam's Club sells them under their Energizer name, but I have to actually inspect the battery to be sure. I may make a trip up there this week if time allows for it.

Right now my MAXX29 give me about 12-13 miles to 50% SoC, and I am estimating that 8VGC will give me 17 miles to 50% SoC, all I need before I charge up. Since I have my rear suspension installed, I can add the extra weight that the 8VGC have in the trunk.

[TheSGC]

I have designed the new battery rack for the 8 volters. My dad is trying to find if any of his friends or coworkers are able to weld it so it's out of my hands for now. If he can't find anyone to do it, I have a few other ideas and people who have volunteered to help out.

I was thinking about using my current pack as cores, but the batteries are still in great shape so that would be a waste. I would only get $72 off, so not much in the long run, so I think I will keep the batteries and create a power bank. I just had a thought of making a battery bank trailer that could be used as portable power.... hhmmm....

I have a little over 1450 miles on this pack and I want to get at least 1500 miles before I change over, but I do have a bunch of EV worthy errands to do that will add up those miles quickly.

I have a deadline of the end of April to get the new pack installed, and that is coming fast. I have collected a few quotes on US Battery, Trojan and Energizer and the Energizer is nearly half the price and has the same specs as the Trojan T-875.

[TheSGC]

It looks like I will be getting the US 8VGC XC batteries. I researched all my options and the Energizer EGC8 is no longer made by US Battery, but Johnson Controls and would yeild about 24 miles to 80% DoD. Not bad, and enough for my normal use, and the price is the lowest.

However, this morning I got a quote from a different US Battery distributor and the price for the 8VGC XC was way too good to pass up. Actually, my tax return covers the difference and I should get about 30 miles to 80% DoD. I estimating my range based on how much power it takes to charge my EV after a run. The 8VGC XC has a much better Puekert number than the MAXX29, so I might be able to get a little more mileage out of it, maybe even decent high way speeds.