Wanting to Start an EV Project
Hey guys!
So I want to start an EV Conversion project but I've ran into one tiny little problem. No offense to all of you EV conversion pros but I haven't been able to find a very thorough "laundry" list of what is needed and a how-to. I would be more than happy to do this myself but I would like to ask a few questions for all of you Backyard EV guys :) 1) What is the full laundry list of parts that I need? I realize that this may be different based upon the car. But it will most likely be related to ForkenSwift. Things I know I'll need: ~Motor Controller ~DC Converter ~Charging System ~Batteries ~Wires (I've read #00 Welding cable???) Oh yea... And I think I'm missing something.... oh yea an electric motor! Anywho, I would greatly appreciate any and all tips that you guys could give me! Oh and one last question that I forgot to add! I have a question from the beer budget EVs. How much would you estimate your EV build would have been if you were charged $25 a battery? |
Wow....here we go. First off, you will not regret building a beer budget EV. No matter what anyone says, GO FOR IT! It's a lot of fun.
In your "Things I know I'll need" list you can do without the DC-DC converter. For any converter with the output you require (I say 40A mininum @ 13.8V), you will pay hundreds of dollars. I went with a group 31 truck battery (free) and a $20 PWM trickle charger (puts out 2.2A). Battery cables can also be free. Make friends with a commercial truck salvage yard. They all use 4/0 cable. With a low budget EV you are likely going to be at 72V, so amps will be a bit higher than normal. Big cable is good for higher amps. My Alltrax AXE7245 (72V/450A) controller was $300 used on eBay. It has been absolutely stellar. I have never experienced thermal cutback in my 3000 lb lead sled, and that says a lot. Go with a forklift motor, if you can find one. Here is an EXCELLENT guide: Using a forklift motor, and choosing a good one - DIY Electric Car Forums MAKE SURE IT'S A SERIES WOUND MOTOR! Don't forget: -A bunch of 1"X1" angle iron, 1"X1" and 1/2"X1/2" square tubing for battery racks. -40-50 4/0 copper cable ends -Various nuts and bolts -Chunk of 1/2" aluminum for adapter plate -A piece of 5/8" particle board from the Ikea "as is" section for a control system mount. (This is my top secret item....shhhhh..don't tell anyone). You can mount ANYTHING to it (controller, contacter, etc with a couple of particle board screws. -Lots of butt connectors, ring terminals, heat shrink, 18 gauge wire. -Potbox. $60 for the PB-6 @ Cloudelectric.com. -vacuum pump. A used Volvo pump from a junk yard/eBay + a $25 vac switch. I will probably think of more..... Good luck! |
EVs are not my speciality, but I'll be looking at your project and eventually I can give you some help. BTW which is the base model for your EV conversion project?
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Well... so far the only things that I have found withina reasonable price in my area would be a forken... sorry, a Geo Metro (I have one but it would not work since the body is bent and rubbing the shocks. Even if I straighten it, I wouldn't want to risk the durability of the body with the load of batteries.) and a 1980 Trecel.
Mechman, I actually read your entire thread on your journey to your eMX-3. The part in particular that I would love to hear your opinion on is the batteries. I know that you ended up switching to AGMs because your "surplus" was just badtruck batteries xD. The question I have is this: My uncle owns a dealership in town. I ran into him the other day and told him about my idea and he told me that he would sell me the batteries at cost ($25!). Mind you, I don't know the exact rammifications of this (the are "reconditioned" with a garauntee that they are in working condition with "several" years left on them, haha... not with an EV in mind ;)). I figured that I probably wouldn't have as much power and possibly less range. The idea though is to get this started, then the money that I would normally put towards gas goes towards electricity, and the left over into a "buy awesome batteries" piggy bank. Ideally, I would love to get a 50 mile range of speeds upwards to 55-60mph ( I would almost never go that fast, it's simply if I HAVE to go on the freeway for some odd reason, like road closures, etc.) so a range of 50 miles at around 37 mph average (speed zones here are 40mph -a good portion- 35mph -a majority - 20mph -short duration- and 45 - not even a quarter mile, I would probably just go 35 in this area anyways) Requirements: Speeds up to 35mph Range: 30 miles eMPG: 60+ (My geo even in it's dead condition and no mods/driving techniques is at 38mpg) Safety! (who needs that!) Would like (ultimately): Speeds up to 65 MAX cruising speed. (Simply to show off to friends and family. Practicality, 60mph) Range: ∞ (just kidding! But seriously that would be a nerdgasm!) 50+ eMPG: 100+ Safety ( Again, what?!) Luxury!!! (Heater/ cushy seats / nice custom interior / sweet paint job!) Okay, with luxury, I'm sure I could get the heater, MAYBE seats, and I've got a buddy that does custom paint jobs! (maybe Ecomodders.com could show up in springfield/eugene area on another EV!) Interior... Well I always wanted to try my hand at wood working but I think it would be best if I went with an ultralight plastic or fiber. Anywho, if you are thinking that my eyes are a bit bigger than my stomach... Probably :P |
Build a gen set trailer so you can have unlimited range when you need it.
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Gen set trailers are beyond the realm of beer budget. The massive charger to make this work puts it way over the top.
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It is still good information to have.
Let me put my "plan" for an EV conversion down so you guys understand where my line of thinking is. I intend to do the conversion on a beer budget. A mix of looking for a used sit-behind electric forklift (so I can scrap that baby afterwards!), and perusing craigslist. I've found some interesting electric motors in my area for under $200 but I know little to nothing about EMs so I haven't really jumped at them. Howard 2 hp electric motor 5hp 3 phase electric motor (most appealing to me so far) Anyways, original plan is to get a forklift, get the needed parts, scrap the lift. This will be either before or after I choose and buy the donor car for the conversion depending on if I can find one of the other for a great price. I have a hook-up for batteries (my uncle owns a dealership and will sell to me at cost of a whopping $25/battery!). The electric rates in my area are $0.0514/kwH and basing the next bit of information off of the eBooger, that would mean a total increase to ~$107.38, which would still be about $130 cheaper than my current gas-gussling car. That includes the PEAK of my electric usage during winter (never above $35, including the $9 delivery charge.) What I would do with that extra $130, save 1/2 of it to invest, the other 1/2 into an "EV Upgrade" account which would get me nice things such as new batteries, upgraded motors, better controllers, better chargers, better etc. xD So I am starting off with a beer budget but the end goal is the sky. |
Don't want to rain on your parade (agree with Mechman - it's a fun project - dive in!), but you need to manage your expectations.
I predict you're going to have a very hard time getting the range you want from the batteries you're being offered. To start, you're going to need to know the rated & actual (tested) capacity of the batteries you have access to. My buddy & I paid scrap rate for the used golf cart 220Ah batteries in the ForkenSwift, and the best range they ever provided (about 3 years ago) was 35-40 km (20-25 mi) when driven extremely conservatively in ideal, warm weather, at a low average speed, probably below 40 km/h (25 mph). With ForkenSwift, we would have been satisfied with a real world working range of 16 km. That's essentially a trip across town & back again. :D |
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