Electric Insight project

[MetroMPG]

My 2 cents... (Don't take this as discouragement!)

I understand choosing an Insight for its light weight (1850 lbs) and aero efficiency (Cd .25, small frontal area).

Seeing how much fabrication you're in for, I think I might have opted to get a 95+ Metro and chop/taper the roof, like Dave Cloud did to make his EV dragster:



(See thread: http://ecomodder.com/forum/showthrea...ropped-90.html )

The end result is also a lot of fabrication, comparable weight, frontal area and drag coefficient (with some additional massaging). But all the other car's parts are easier / cheaper to get.

I'm still happy to see an Insight going the EV route! Looking forward to your project.

[tscheerer]

Thanks for the comments! Yes, this did come from Brent, it seems he is the king of Insight parts. On the chopped Metro, that looks cool. My experience is in mechanical work, so I'm up for that, however body work is not my bag. The only significant exterior issue should be the headlights. Since the OEM ones are high, the plan is to retrofit from another car. This should give it a more unique look too. Also have access to professional chassis builders for any fab work I can't handle, which will surely be needed. The initial plan is to fab mounts off the OEM mounts for the motor/trans, then splice together the CV shafts with chrome moly tubing. Once the drive train is in, the rest will follow. If the car is about at the 1800 lb curb weight with 400 lb of batteries, then it's all good.

[discovery]

What you got i think weights about 800 lb. Good luck with the project take pic we all are very interesting in pics, it's all about seening, understanding and believing.

[tscheerer]

Now have the major components of the EV drive train, as shown in pics. The motor is an Advanced 8" 4001a, including the adapter and mid 90's GM manual trans. The controller is a Curtis 1221c at 400a, which hopefully will be enough to drive the Insight at around 2k lbs. The current issue is getting the title in my name. Missouri requires an inspection and changing over the title in 30 days or penalty of $25/30 days late. The car is not ready for an inspection and won't be for a while given the current state it's in. If anyone has been through this and has tips or workarounds, I'm all ears.

[bennelson]

A Curtis controller running 72V was great my my Electro-Metro, which is around 2000 lbs. I have been very happy with the Curtis controllers. You shouldn't have any trouble there.

[MetroMPG]

What are your performance/range goals or needs?

Other than stating that you were starting at 72v and maybe going up from there, I'm curious to know what you're working towards.

[tscheerer]

Well, this is my first EV build after many years of working on and building ICE cars and race cars. It started as a father/daughter project to build a unique car for her. My minimum goals are to prove that I can do it and that the car be capable of transporting her to and from school daily, which is about a mile each way. Once it's on the road, I plan to work on mileage, no desire for performance as I get that from ICE vehicles. My daily commute is about 22 miles round trip, and I don't expect it to make that in it's first form. Ideally, the plan would be to upgrade from lead to a better power source in a few years as batteries mature and maybe then make it my daily driver.

[rmay635703]

Originally Posted by tscheerer

Now have the major components of the EV drive train, as shown in pics. The motor is an Advanced 8" 4001a, including the adapter and mid 90's GM manual trans. The controller is a Curtis 1221c at 400a, which hopefully will be enough to drive the Insight at around 2k lbs. The current issue is getting the title in my name. Missouri requires an inspection and changing over the title in 30 days or penalty of $25/30 days late. The car is not ready for an inspection and won't be for a while given the current state it's in. If anyone has been through this and has tips or workarounds, I'm all ears.

In my dealings with the wisconsin DMV (which is totally different) My recommendations are as follows

The best source of information is unfortunately the DMV unless you can find someone who built a "hobbyist" car in your state.

If you do ask the DMV questions, ask at a NON-local, DMV, remain annoyinmous and ask how your situation would be handled hypothetically, don't mention the electric bit, just ask what happens if you buy a car that needs the motor replaced and drivetrain and is going to take longer than 30 days to source before it will be road ready.

They should be able to state how that is handled hypothetically.

[MetroMPG]

Well, you should have no trouble with those goals.

I was just curious. Seems like a lot of 1st time builders have expectations out of line with (a) reality, or (b) their budget (often one in the same!).

[tscheerer]

Got the title done yesterday, but not without a few hitches. After studying on the MO state website on titles, figured out there is a title only transaction that can be done. The form provided on the website says that inspection, insurance and property tax receipts are not required for this transaction. So off to the licensing office when it opens at 8a. After looking the paperwork over, the lady says since the original title is out of state, I need an ID/OD by an inspection station to verify the VIN number on the title matches the car. So I stop by the local station and make an appointment for the afternoon. Get there with the car on a trailer since it's not functional, and the inspection guy says he needs to get the mileage. Something about the book saying on rebuild cars the mileage has to be verified on the ID/OD. Even though the car isn't wrecked and has a clear PA title, if he can't get the mileage, I can't get the ID/OD. The car has the original computer per the seller, but part of the wiring is gone and it's disconnected. I haven't put power to the car since I've had it, so no idea if it's going to work. I get the computer connected to the one cable that's there and get a battery to connect to the battery cables. Turn the key and .... hooray, it works! So the guy gets the mileage and I get the ID/OD. Then the car has to be put away and it's back to the license bureau. At this point I'm thinking what the next hurdle will be. Thankfully it's all smooth from here and no issue completing the title only transaction, finally done at 4p. Now in a couple weeks I should have the title in my name and the building can continue!