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Old 02-25-2015, 03:04 PM   #1 (permalink)
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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.



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.



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

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Old 02-25-2015, 04:06 PM   #2 (permalink)
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That is quite the transformation haha. And a 1200A controller, that must be fun.
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Old 02-25-2015, 04:45 PM   #3 (permalink)
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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



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...



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



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...



Here is the new sheet metal in place



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



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

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Old 02-25-2015, 05:15 PM   #4 (permalink)
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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
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Old 02-25-2015, 05:22 PM   #5 (permalink)
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Quote:
Originally Posted by Old Mechanic View Post
If you don't want to answer I understand, but how much would a person have to pay for those batteries?

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.
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Old 02-25-2015, 05:35 PM   #6 (permalink)
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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.



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



a couple wires



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



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.



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



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.
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Old 02-25-2015, 06:27 PM   #7 (permalink)
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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.



My used hood still needed love



and so did my new used door.



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



Finally, some paint.





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Old 02-25-2015, 06:45 PM   #8 (permalink)
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Looks like you have a rather substantial "work shop" going there.
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Old 02-25-2015, 06:58 PM   #9 (permalink)
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You do beautiful work!
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Old 02-25-2015, 07:05 PM   #10 (permalink)
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Quote:
Originally Posted by Old Tele man View Post
Looks like you have a rather substantial "work shop" going there.
It's getting there, but I could always use more, lol..

I polished up the tail lights for that newer look



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



I cleaned all the old urethane off of the windows



and polished the glass



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.



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






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