Second conversion, basic DC
 

I found this 1995 Metro on craigslist, and drove to Santa Cruz with my trailer in tow in case it looked like a good deal. It had been converted back around the turn of the century, and it was wrecked, according to the add. I saw that there was a Raptor 1200 amp controller, an ADC 8" motor, and a Manzanita pfc 20 charger, so when I negotiated the price down to what I would pay for just those components, I loaded the wreck up onto my trailer and brought it into my shop here in Sacramento.

http://i1242.photobucket.com/albums/...5860547701.jpg

I reworked this car, replaced the 1750 lbs of flooded lead acid batteries with lithium, gave it my treatment, and prettied it up a little.

http://i1242.photobucket.com/albums/...g?t=1388867042

I will post the rest of the build and all the details here very soon, stay tuned

That is quite the transformation haha. And a 1200A controller, that must be fun.

Yea, the 1200 amps is far more than those tires can put to the road...

So, first order of business on this little rig was to go to pick n pull and grab a door, fender, hood, and bumper. The suspension was blasted too, so I picked up a control arm, strut, and axle too. After I hammered and pulled the core support straight, I went ahead and hung the sheetmetal

http://i1242.photobucket.com/albums/...5860620995.jpg

Next, I gutted the engine compartment. This poor car had been converted with duct tape, deck screws, expanding foam, and an old steel shelving unit from UC Santa Cruz. Super hoakey job. I was after a quicky basic conversion as well, but not down to those standards...

http://i1242.photobucket.com/albums/...9439249664.jpg

While I was working on other parts of the car, my lithium batteries arrived from China 45 100 AH batteries

http://i1242.photobucket.com/albums/...4005198644.jpg

The lead batteries that this car came with were installed into a big hoakey box that was installed through a gaping hole in the rear of the car. In this pic, bracing for my new pack has been added in preparation for some new sheet metal. It almost looked like the hole had been cut with a jackhammer...

http://i1242.photobucket.com/albums/...8844580086.jpg

Here is the new sheet metal in place

http://i1242.photobucket.com/albums/...0317128169.jpg

View of repair and new fabrication work from the bottom of the car

http://i1242.photobucket.com/albums/...0317047760.jpg

Now the new lithium pack is in place. 350 pounds of lithium is a lot nicer than the 1750 pounds of lead.

http://i1242.photobucket.com/albums/...g?t=1374534090

If you don't want to answer I understand, but how much would a person have to pay for those batteries and how long would you expect them to last?

regards
mech

Lithium batteries cost between $1 and $1.5 per amp hour. These ones are 100AH each. These ones were about $125 per battery. (100AH times $1.25) I have 45 of them, so $5625 for the whole pack.

Since this is just a basic conversion, The engine bay just got a coat of primer, and a little rattle can black down around the bottom. This car was rust free, since it is from CA, so there was no rust for me to treat. Nothing pretty here, just function.

http://i1242.photobucket.com/albums/...g?t=1379038823

Here is the charger, controller, motor, and transmission in place

http://i1242.photobucket.com/albums/...g?t=1379038927

a couple wires

http://i1242.photobucket.com/albums/...g?t=1379185716

I re used the same hoakey vacuum tank and vacuum pump. A little noisy, but no need to spend money on a new pump and tank

http://i1242.photobucket.com/albums/...g?t=1379188623

I needed a new DC DC converter since my pack voltage is now 144 volts instead of the 120 volts that it was with the lead. The old DC DC was only good to 130 volts.

http://i1242.photobucket.com/albums/...g?t=1379464300

220 volt charging inlet. My welder extension cord plugs right into this.

http://i1242.photobucket.com/albums/...g?t=1380067237

I took it for a test drive to make sure all was well, and I giggled like a girl when I was able to roast the tires at 25 mph without popping the clutch. The smell of burning tires always makes me cheerful. I like to test drive my builds like this before I make them pretty, which is the next stage.

In order to make her look pretty, I had to do a bunch of sheet meta repair, and then skim everything with a layer of body filler. This quarter panel was messed up from the wreck that caused it to be up for sale The new door and fender fixed a lot of this side, but the quarter panel still needed lots of love.

http://i1242.photobucket.com/albums/...122_182825.jpg

My used hood still needed love

http://i1242.photobucket.com/albums/...123_165500.jpg

and so did my new used door.

http://i1242.photobucket.com/albums/...125_192245.jpg

and the bumpers, and the rest of the car...

http://i1242.photobucket.com/albums/...207_104015.jpg

Finally, some paint.

http://i1242.photobucket.com/albums/...217_164643.jpg

http://i1242.photobucket.com/albums/...220_083736.jpg

http://i1242.photobucket.com/albums/...220_083659.jpg

Looks like you have a rather substantial "work shop" going there.

You do beautiful work!

It's getting there, but I could always use more, lol..

I polished up the tail lights for that newer look

http://i1242.photobucket.com/albums/...g?t=1387926254

and upgraded to LED. I went with LED lights throughout the car

http://i1242.photobucket.com/albums/...g?t=1387926556

I cleaned all the old urethane off of the windows

http://i1242.photobucket.com/albums/...221_092554.jpg

and polished the glass

http://i1242.photobucket.com/albums/...221_101618.jpg

I made package deal with my local glass shop and had them tint my back three in limo, my door windows in the lightest shade, and put a limo strip across the top of the windshield I bought the windshield from them too, so when I went back to get all my glass, the new windshield was ready as well.

http://i1242.photobucket.com/albums/...g?t=1388111102

Now, it is a happy running EV! 1200 amps at 144 volts is way overkill in a little Metro, but it sure is fun.

http://i1242.photobucket.com/albums/...ejpg1-1272.jpg

http://i1242.photobucket.com/albums/...gejpg1-659.jpg

http://i1242.photobucket.com/albums/...ejpg1-1467.jpg