Electric car conversion: Project ForkenSwift

[bennelson]

Those rims are gorgeous!

I'm just a big jealous here. All I did on the Electro-Metro was cover my ugly rims with cheap-but-nice-looking plastic hub caps!

[MetroMPG]

Yeah - they sure are purdy.

Looking this nice, they caused me to go around and clean up the outside of the car a little bit. First time this year!

[MetroMPG]

The RE92 tires seem to be performing as well as my butt-o-meter predicted.

Before/after comparison:

119 MPGe / 281 Wh/mi in yesterday's use (first full cycle with RE92's)

... compares with ...

103 MPGe / 325 Wh/mi in a drive/charge cycle from last week with the old tires, that had very similar distance/usage and ambient conditions.

That's a 17% improvement in efficiency (or potential increase in range)!

Of course, that's not at all a scientific comparison.

But I can say for certain that on routes where I have memorized "glide" points (ie. where I let up the accelerator to coast up to certain turns or stops), I'm now coming in way too hot. Have to adjust my driving, or get regen to take advantage of the energy that used to be lost to rolling resistance!

[MetroMPG]

Happy Birthday ForkenSwift!

October 2011 marks the 4th year since conversion. Coincidentally, it just passed 6000 electric km (~3700 miles) as well.

Looking back:

• It's averaged 1 minor problem per year, none of them expensive (1 shorted wire, 1 DC-DC module, the always-slipping-apart coupler, and a potentiometer mis-adjustment)
  
  I'm not counting the tranny oil leak, because the ICE version would have had the same problem.

• Energy consumption average (4 years) has been 195 Wh/km, or 318 Wh/mile. After recently changing to the LRR RE92 tires: 281 Wh/mile (average of the last 6 drive/charge cycles)

• I wish it had regenerative braking, but don't plan on adding it - TMP! Too Many Projects!!

So, seems fitting to say thanks again to everyone who encouraged this project along in the early stages.

Who knows if the car will be around for another 4 years (rust!).

Lately I've been dreaming of a ratty electric 40's or 50's pickup. Something like this would be purrrrrfect, and more in keeping with how I actually use the ForkenSwift:

(They're really not horribly heavy - 2800-3500 lbs, including about a 500 lb iron engine block!)

But that will likely remain just a dream. (TMP!!!)

I also dream of hybridizing the Firefly or the Insight with 20 km worth of EV mode, and then I could reduce the fleet by 1...

Anyway, if anyone wants a more flowery / detailed retrospective, I have posted a page on FS.com: 6000 km retrospective - ForkenSwift.com

[electricman]

Originally Posted by MetroMPG

My electric car's DIRTY LITTLE SECRET

It involves Big Oil...........

Oil leak! (From the transmission.)

Daren, Mine has a leak too - but - it is in the Brake Fuild System - I think it's time to decide if a New Master Cylinder and Vacuum Booster would stop the problem (Besides giving the car a newer look under the hood!)

[MetroMPG]

Hi Robert -

I had a VW Rabbit with a slightly leaky master cylinder - not a corrosion problem.

It lasted for quite a while like that until one day I had no brakes! (No hydraulic brakes.)

[MetroMPG]

The wee blue beastie goes into hibernation today - I cancelled the insurance.

Picture placing a sugar cube in a dish of water. That's a close approximation of what I imagine the car will do if subjected to another salty, slushy, rust-belt Ontario winter.

Not 100% sure I trust my memory, but I think this is the first winter off the road since the car was converted.

[MetroMPG]

My bad: Daox tells me the car hibernated in one other winter.

Yup - '08/'09: http://ecomodder.com/forum/showthrea...html#post80777

[mechman600]

What an awesome read! I have known about the Forkenswift project for a while now but only now sat down and read the entire build thread. I am a mechanic by trade but have yet to convert anything. In my head I thought I knew everything there was to know about EV conversions from years of research while attempting to build enough courage to go for it, but I honestly have learned so much from you. A hearty thank-you!

Too bad about salty Ontario ruining your car. I grew up near Winnipeg where it's much the same but now live on the BC coast where rust seems to be a thing of the past. The one place in Canada like it.

Take care!

[MetroMPG]

Hi Mechman - you're welcome! Take the plunge - it's a fun project.

Lucky you , living on the west coast. I've spent some time out there and it sure is nice.