EV Conversion: Peugeot 306

[nickfarmer]

I'm just starting my EV conversion of a Peugeot 306.

In an attempt to keep the cost as low as possible I am intending to use a forklift motor, but I'm not quite sure where to start looking.

I'm aiming for a top speed of about 45-50mph (the faster the better), and a range of about 30 miles. This is a bit optimistic on my budget, so these are aspirational goals.

The current situation is that the engine (with faulty head gasket) and gearbox are out of the car and seperated, and the next step is to find an appropriate motor.

I've gathered from Forkenswift, the Electro Metro and MPaulHolmes' Beetle that I need about an 8" motor rated at approximately 48V. Does anyone know of any sorts of places that might have one going? as I'm not quite sure I want to take my chances at a scrapyard!

Here are some pics of the car, it's pretty good for £150, but we did have to tow it 40 miles back on a trailer.

[SVOboy]

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Good luck man! Looks like it will be a great project, be sure to keep us up to date with every little thing.

[bennelson]

The car looks great! Complete with a sunroof!

Just read through the other EV build threads on here and don't make the same mistakes. You'll do great!

Oh, and throw one of those Cougar controllers in there!

[nickfarmer]

I'll definitely try to use a Cougar. I don't think my budget allows me to be decadent and buy a controller.

The sunroof is one of the best things about the car, way better than A/C.

Thanks for the advice.

[vinny1989]

Hmm, Cornwall you say? Isn't it a bit hilly around there? I would suggest the highest voltage design you can afford.

(Going from the forkenswift, electro metro and super beetle build threads - it seems higher voltage is better for hills)

Good luck though, and keep us updated

[Wilden]

Sounds like a great idea mate, I hope you manage to get it working to great effect.

I found an ebay seller a while ago who has decent sized motors, though unfortunately he/she doesnt say the voltage or whether they are AC/DC. Might be worth a look, but not cheap, I think the prices have gone up recently.
eBay UK Shop - electric-motor-man: electric motor, single phase electric motor, three phase electric motor

[order99]

'Single-phase' and 'triple phase' probably denote AC, but i'd PM him just to be sure.

[nickfarmer]

I've just got the gearbox off the engine and connected up the 12V system, so the motor is next to do. Also I just bought "Build Your Own Electric Vehicle" from amazon, but nothing on Forklift motors or home built controllers!

I've just phoned a guy in Plymouth who has a wrecked 48V forklift coming in tomorrow.
Does anyone know what I should watch out on the motor, past about 10" in diameter and sturdy?
The engineer who will be making the gearbox adapter says to try and find a flange mounted motor.

[bennelson]

My Metro has about a 10" diameter motor in it. That is the BIGGEST motor you can put in a Metro.

One thing to make sure of - motor size vs where your wheel driveshafts are on a front wheel drive car! (This car is front wheel drive, right?)

If it is, measure from the driven shaft on the transmission out to the front wheel drive-shaft on the engine/motor size. Make sure your motor is a smaller diameter than that, if not, your driveshaft and motor will be in the way of each other, and you can never put the car together!

On a rear-wheel drive car, it's really not an issue at all. In fact, a rear-wheel drive conversion is great because you CAN put in a huge motor!


Also on the motor, look at the brushes. They should be nice and beefy looking. More brushes are better. 6 of them, or 4 pairs, are better than 4 single brushes.

Motors can have bolt holes on the face of the drive end of the motor, or under the motor as a "foot". Bolt holes on the face make it a little easier for mounting straight to an adapter plate on the transmission.

If you have a "foot" under the motor, you will need to custom-build some sort of support that goes under it.

[nickfarmer]

Thanks Ben. Better go and check the drive shaft position now it's stopped raining.
The 306 is front wheel drive, and probably slightly bigger than a metro.