David's 2001 Civic EV (80-100 mile range; 65+ MPH; 8 second 0-60)

[TheSGC]

This morning I mounted the transmission to the Warp 9 and the alignment seems perfect!


There was no vibrations while in neutral or in gear, and just some transmission noise because it didn't have fluid it in.

I am going to try to install it on Wednesday and get my EV running this week. Tuesday night my dad and I will get the motor and transmission outside then I'll cover and Wednesday I will install it.

[mechman600]

Nice! Are you going to dial up the Zilla or wait a while first? I vote do it now!

[TheSGC]

Originally Posted by mechman600

Nice! Are you going to dial up the Zilla or wait a while first? I vote do it now!

I'm probably going to set the Zilla to 650A until I get water cooling. I want to make sure the alignment and transmission are fine before I start hammering them again.

I've been reading up the thread on Stream lining a 2001 Civic and I'm getting some ideas to do areo mods this spring/summer. If a few aero mods get get a gas Civic from 38 MPH to 50 MPG then it would do wonders to my EV! If I could get down to 200 wh/mi that would give me a SAFE 100 miles range! This past fall I estimated about 82 miles without heat and 52 miles with heat on full. And now I believe my coupling issue added considerable drag to the EV.

[justme1969]

too many pages here to read just now but its great.
I wanted to add a similar hybrid drive to my sisters boat.
ok its a yacht.
Anyhow 2 454 commanders suck so much fuel it barely gets to the Gulf and its time to drop another $300 into the tanks to fish with.
I felt if she could engage a PTO and run electric for the No wake sessions It would save 50 gallons or so per trip.
She wouldnt let me do it...

[mechman600]

Originally Posted by TheSGC

I'm probably going to set the Zilla to 650A until I get water cooling.

Any idea what you are going to use for a pump and radiator/heat exchanger? Will it circulate on a 100% duty cycle or will it temperature dependent?

[TheSGC]

Originally Posted by mechman600

Any idea what you are going to use for a pump and radiator/heat exchanger? Will it circulate on a 100% duty cycle or will it temperature dependent?

I am going to use the existing radiator since it's already in the EV. I haven't picked out the pump yet, I am going to look at PC water cooling motors or just get another 12v pump like what I am using for my heating system. I haven't decided if it will run 100% or be temp dependent. Most likely I will have it 100%, once my EV is back up and running I am going to monitor more drives and check the temperatures of the Zilla.

[TheSGC]

It was really nice today so I decided since I didn't have classes I would start putting my EV back together.



Last night my dad helped me move the Warp 9 from the basement to outside my EV. Then this morning I got the transmission out and mounted it to the Warp 9. Then I had to drill new holes on my rear motor mount because the Warp 9 has a different rear bolt pattern.

Then after lunch we used the engine hoist to install the motor and transmission combo into my Civic. It went pretty well, after a few minutes we had two of the four engine mounts bolted in. The rear mount is always difficult to do but my dad was able to help after he got home from work.

I also had to get a new speed sensor for the Warp 9. My old sensor was too small for the 1.125" shaft so I got a new sensor from Evolve Electrics with 2 day shipping and it arrived as I was installing the motor. It took 30 seconds to install as the Warp 9 was built with bolt holes for a speed sensor.

Now I have the Warp 9 installed, the axles in and the tires back on the EV. Later this week I am going to try and get more things installed, including better insulation for the heater pipe and batteries. I am really hoping to start commuting again in the next week, I just need the weather to cooperate long enough to finish the last 10%.

[TheSGC]

Tonight I had a bit of time to put some more things together. I got the clutch slave cylinder installed, the linkages to the shifter bolted in and cleaned a few things up.

I need to pickup some tubing insulation for my heater and locate the wire for the tachometer. Then I can put the controls back in!

I also have to insulate the battery pack since it still gets cold and the jury is still out on if the CALBs can be charged under 32F with C/10 charging current.

[TheSGC]

I got my EV back together!

I got home around 2 PM today after some meetings and picking up pipe insulation. I was able to insulate the the entire heating system which should help get the heat faster and stay longer.

After that I installed the control tray and started wiring everything up. I finished at 7 PM tonight, which is when the EV got off the stands and is now on the ground.

I have the EV on the charger now and tomorrow I will take it out for a spin. Since this is a long weekend I have a few other things I want to do:
- Hookup Tachometer
- Insulate battery pack
- Install Volt and Current meters

[mechman600]

You remembered to reverse the brush timing for the [backwards] Honda direction, right?
I'm guessing you did (as you are well versed in all things EV), but I just want to make sure. Forgetting this will make for a nice spark show from your brushes when you give it the beans.

Looking good! I'm very jealous.