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Old 04-14-2012, 08:29 PM   #1 (permalink)
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Talking New Guy to EM

I've been lurking here for some time. I've been interested in an EV conversion for several years. I've been reading in the Fossil Fuel Free section for a good while. I originally bought a 1996 Saturn SL1 with overheating issues. Fixed it and have been driving it on and off for three years now. My high gpm so far is 38 mpg.

I now have a 1998 Saturn SL2 for my EV conversion. I have a DC motor and just ordered and received an Open Revolt Cougar, 500 amp controller. My motor adaptor is being fabbed by a machinist friend right now. Still got a way to go but am excited to get it on the road.

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Old 04-14-2012, 11:51 PM   #2 (permalink)
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Sounds like you're off to a good start. Tell us about the plans for the rest of the EV drive system.
Current project: A better alternator delete
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Old 04-14-2012, 11:58 PM   #3 (permalink)
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you came to the right place.
very smart guys here!
MetroMPG: "Get the MPG gauge - it turns driving into a fuel & money saving game."

First: ScangaugeII

Second: Grille Block

Third: Full underbelly pan

Fourth: rear skirts and 30.4mpg on trip!
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Old 04-15-2012, 10:47 AM   #4 (permalink)
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I'm going clutchless with this project. I scavanged the Spline coupler from the lift truck when I got the motor. I scavanged the spline coupler from the clutch. My machinist friend is working on mating them together to form my coupler.

I've read lots on batteries and I plan to purchase LiFePo batteries for the battery pack. I'm planning on a 120 volt pack. The motor is rated for 48 volts so I can over volt with advanced timing. I have already cleaned and painted the motor. I replaced the bearings and was able to advance the brushes very easily while the motor was taken apart. I used Autocad to create a template of the existing hole patterns and then draw new holes for the advance. I used ahole punch to make holes in the paper pattern and then used a spring punch to mark the new hole centers.

My machinist is also making me a 6 tooth tach ring so I can use a pickup to use the Saturn's existing tach. It's been done before and I am following the directions I found on line.

I'm trying to involve my two oldest sons. They are teenagers and each has interest. The oldest(16) has interest in the controls and the youngest has interest in the mechanical. Both may be able to earn a merit badge from their involvement.

I have started an album and pan on dowloading pictyres soon.
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Old 04-15-2012, 02:35 PM   #5 (permalink)
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Welcome to EM.

Cool project!

I will be glad to see pics
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Old 04-16-2012, 10:51 PM   #6 (permalink)
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Just put a few pics in my album. These pics are from the beginning of the build. I will add more pics as the build progresses.

Excuse me, sir. Seeing as how the VP is such a VIP, shouldn't we keep the PC on the QT? 'Cause if it leaks to the VC he could end up MIA, and then we'd all be put on KP.
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