EV Dodge Neon Conversion
 

Hi Everyone!

My new friend Tom G. is converting a Dodge Neon to be a 300+ volt AC electric car.

We are going to be making videos showing how to do a car conversion, and post them on YouTube.

I will start off by embedding videos here.




Perhaps we could get a LoveJoy sponsorship out of this one!

Great idea, Ben!

I have to repeat a tidbit a professional EV builder told me a week or so ago, which was a warning against using Lovejoy couplers in high powered conversions. He seemed convinced they would wear out the spider. I can't say whether that's true or not, and didn't think to quiz him on what type of spider material he was talking about.

Meh, as long as the coupling is big enough (or designed for the torque) its fine. We use generally the same type of coupling in the conveying industry and we're transmitting thousands of ft/lbs of torque.

Meh, I stand corrected then.

I have heard of a lovejoy failing on a low-power EV though (72v). Can't say why, of course.

Ben's going to become famous with his video series. His friend Tom, too.

This is, of course, just the first of many videos.

Comments like asking if a Lovejoy coupler works or not are all appropriate questions.

A big part of these videos is to encourage discussion of vehicle design, and encouraging others to get out there and do it!

Well, I can't speak for the love joy specifically. Ours are a bit different in design and are made to handle the torque (up to 11,000 ft/lbs or 15,000 Nm).

rexnord.com | Wrapflex

http://pt.rexnord.com/products/image...x-coupling.jpg

I wouldn't worry about the Lovejoy so much as I would relying on such a small end-face seam weld for power transmission. It might be more prudent to use a larger spline size lovejoy and lathe it to match a slightly larger size, then mill the spline adapter to include a keyway.

Of course that really depends on how much force it took to press the spline bushing into the lovejoy before you welded them together.

Relevant project link where the motor and transmission were coupled by interference fitting a spline adapter onto the motor shaft. Part was precisely machined so that it could be heated, pressed onto the shaft, and then cooled.
http://evdrive.com/BMW_project/ACmotor.html

Finally at home so I can view the video. Very nice!

pretty cool. I was always curious how to do this. I agree with CaptainSlug, I would have expected a keyway ground into the spline off the clutch plate, but as long as the welds are strong enough, it doesn't matter!
Does the electric motor drag at all when you shut it off? I thought the EOC-ing would still be something you'd want to do if you could, and wouldn't that allow you to change gears? Of course, putting a clutch on that would be very hard.

Oh, and thanks for the video. We will look forward to future installments!

Installment #2
 

Video 3

Video 4

Video 5

http://www.youtube.com/watch?v=ffAC5zXhwSQ

great! ...another project to follow. can't wait to see more.

Ben-what type of work do you do?

I work in video, so I do have a decent camera, lights, and microphone.

This is still pretty slapped-together, but better than the first couple Electro-Metro videos I made.

It's nice to have somebody else to videotape instead of turning the camera on myself.

You know if somebody wants to get their hands on this type of project the bolting of the motor to the transmission is what most likely stops them. But since you gys tackle the hard parts first I could see a lot more people doing this.

Wow - this is flying right along.

Not using the MetaCafe embed code?

Switched them over. #5 isn't on MetaCafe yet.

Awesome. Completely, Totally, awesome. Maybe I shouldn't put this idea in your head, but these videos are worth paying for. Thanks so much for sharing so freely.

I like how you show your Tim 'the tool man' Taylor moment with the hole saw. :p

I like how you're eliminating the machine shop expense with the adapter plate construction.

Tom's welding ability is way better than Darin's. :D ;)

I would LOVE to keep making more videos like this, but I do have to stay busy with earning actual money to pay the mortgage, etc.

One reason why I am trying to run more videos through Metacafe, is that there is the possibility of earning a little money.

I had thought about making a series on EV Conversions, and selling them on DVD, but this info is going to be constantly improved and updated, so DVD is not the best for that. Plus, I would have to actually manufacture, mail, take payment for, do all sorts of other work selling DVDs.

If anyone has some good ideas on "monetizing" these videos, please let me know.

I want to get the info out there, but I could do a whole lot more of it if it were at least part of my income.

I don't know about making money right this minute-but if you wait until you're done before releasing the DVD you should have one heck of a presentation as well as 'proof of concept'(the finished vehicle). If you know how to include File Folders on a DVD (for the DVD-Rom drive) as an Extra, you could include Links to the manufacturers you used-for a possible Advertising fee from same. Add in any Schematics for wiring, any homeade controllers/converters and Templates you used in the process, and you would definitely have a nice, salable package!

In the meantime, do you have a private Blog/Website you can link these videos to? If so, A Paypal donation button would help defray your expenses a bit. Youtube doesn't allow direct Weblinks, I don't know whether Metacafe has a similar policy or not...if they do allow it, Direct Link to the Website (and Paypal Link) from Metacafe would be the way to go.

lovejoy
 

As far as the spider inside the lovejoy getting worn out (is it an L-110?), Lovejoy makes a bronze spider too. It can handle a lot more horsepower.

It was an EV build day today.

I worked on trailer lighting for my car and getting the rear batteries properly bolted down.

Tom had his batteries, motor, and transmission rigged up for bench testing. The motor is bolted down to the adapter plate with the Lovejoy coupler going to the transmission.

I apologize for the picture and sound quality on this. I brought one of my camcorders with me, but forgot to bring a videotape!

I used the motion video feature on my point and shoot still camera to get footage of Tom test-spinning his motor.

In the first video, Tom is just spinning the motor against the transmission. In the second one, he is running the motor with the transmission in gear - not sure which one. I think it was third or fourth.

http://www.youtube.com/watch?v=LsAIqnqKulE
http://www.youtube.com/watch?v=WsU3U9MFJAA

Tom, I have a few questions on for you. Can you give any more information on the motor? What HP, voltage, wye or delta, Base RPM, Max RPM, FL torque, is it inverter duty or just steer me toward a manufacturers data sheet.

Also, are you going to try to run this with a VFD by direct feeding the DC bus? If so, what manufacturer's VFD are you using?

I hope I'm not getting to technical. I have thought about doing a conversion along these lines. Used/surplus AC motors are cheap on EBay, VFDs too. I know of only one other person that has done an industrial AC motor/ industrial VFD conversion. He used an ABB inverter duty 10 HP motor and a 30kW Danfoss VFD if I remember correctly.