My EV conversion...
Phase 0
Currently I am planning the EV conversion, and counting on costs and what parts to use but due to the compulsory military service we have here in Sweden the conversion can start earliest January 2009. I would love to start right away, but the approximately $ 300 I get per month for doing this army duty isn't enough to both cover my standard expenses and fund an EV conversion. That's the timeline, first military service, second I have to get a job, and third I'll start the conversion right away.
Plans
This is only planning, and will be updated ahead in time. Se this as my own template...
Cost
This list is based on the list from Gav's
EV conversion and is translated from New Zealand dollars to US dollars using
XE's currency converter.
I'm not sure if this covers all his expenses but it will give me and you a hint
of what expenses there are.
Lines in italic are my own calculations, based on Swedish store prices
(or US market + shipping) and recalculated to USD with the same currency converter
as before.
Lines in green is items already purchased.
Car (Veteran car (30yrs+) or small aerodynamic car) 10 000 SEK
/ $ 1588 [Link]
Advanced DC 203-06-4001 Motor + Curtis 1231C Controller 29 090 SEK /
$ 4620 (with shipping and customs fee) [Link]
Curtis PB6 Pot Box $105
Ventilation fans and controller (cold country, need to heat the batteries
in winter and vice versa in summer) 700 SEK / $ 110 [Link]
Turbo timer + shipping 1000 SEK / $ 160 [Link]
Motor Bracket/Mounts $60
Gearbox/Motor Adapter Plate $834
Cheap Battery Chargers + installation material and power strips (13) 4510
SEK / $ 708 [Link]
Thomas Vacuum Pump & Switch $83
Digital 200v DC Voltmeter $18
Digital 500A DC Ammeter + Shunt $56
200V DC 10A Solid State Relays (2) $116
160V 250A DC Circuit Breaker $131
SW200 Main Contactor $103
Extraction Fans for Battery Box $14
High Voltage Fuses & Holders (2) $135
70mm2 Welding "Main" Cable (12m) $152
Inertia (Crash) Cut-off Switch $84
Choke Cable (for circuit breaker) $19
Aluminium Cooling Plate $51
MDC2485 Deep Cycle Batteries (12) $1936
Transport to Swedish Motor Vehicle Inspection Company for Certification
(twice!) 800 SEK / 125 $ [Link]
Certification (need a road legal car, right?) 2 280 SEK / $ 356
[Link]
TOTAL (so far)....................approx $ 11,955 USD
These calculation is worst case, hopefully some things can me bought used to keep costs down. And as i purchase things in large volumes I can hopefully get a rebate.
Savings
I spend about 1200 SEK ($ 191) every month on fuel (100 liters / 27 Gallons), even more when I can afford it. This means that if I buy a veteran car and convert it for under 100 000 SEK ($ 15,900) the EV will have paid for itself in 6 years (including the saving for using a "no-tax car"). And the fact that I'm saving the planet and keeping gas prices down (as demand decreases with a percent of a percent of a percent of a... etc).
Car
I'm looking for a decent small or mid-sized car built 1979 or earlier.
There are many reasons why but the main is that all cars that are 30 years or
older is not tax-liable and you'll only have to take the car to the vehicle
inspection every second year instead of every year.
Further old cars are lighter, easier to register as EV's, easier to tinker with
and in my opinion better looking if in good condition.
But due to crash safety and ride comfort a modern aerodynamic small sports car or hatchback is also an alternative!
The conversion itself
The plan this far is to keep it simple and legal. Hopefully the car passes the Swedish Motor Vehicle Inspection Company Certification Test without any problem, after all everything will be checked with them before the actual start of building.
One problem is the bureaucracy, especially when it comes to the brakes. The sollution is to first register the car as a "light truck" aka remove rear seats and install a "wall" behind the drivers seat, as protection against cargo. This will cost about 1540 SEK / $ 240 extra as I have to cetify the car twice!
The chargers shall be 13, one for every battery (12 to the motor and one for the lights, stereo etc) mounted inside the trunk. Inside the old fuel filler cap I'm planning on mounting a 230v electric socket, allowing me to charge the car anywhere basically. The batteries shall be mounted as many as possible under the bonnet and the rest in the trunk, hopefully the weight distribution will be similar to what it was before.
In the engine compartment the heater will be converted to electric and a vacuum pump for the brakes will be installed. Servo, AC etc isn't anything I want in an EV so if they would exist, they will be removed.
I want to keep down the number of electronic gizmos, an alarm, electric windows, central locking and a stereo is about all I'm planning to install. For better energy efficiency and a more modern look all lights that is in regular use is going to be switched out and replaced with LEDs.
A simple mp3-on-cd playing stereo, with 5,25" speakers in front and 6,5" in the rear will hopefully be installed.
Performance
In the first car I would be satisfied with a top speed of 70 km/h and a range of 50 km, but the goal for an everyday EV is still 100km/h and a range of 200 km.
Garage & Tools
This is another problem right now, but I'm looking for a cheap and "conversion friendly" garage. I've borrowed a garage from my wonderful girlfriend (actually from her parents), still don't know if they will let me have it long enough for me to do the EV conversion... Worst case scenario is that I would have to rent a regular garage, which would cost me about 1200 SEK ($ 190) per month and definitely delay the conversion.
Right now I have managed to get a pretty decent set of tools exept a welding machine and a lift for the engine. Maybe Santa is nice next year!
Display
When the conversion is complete it's time to hit the roads, and I think with some nice tweaks and the electric engine the car will get some heavy attention on car meetings...
Documentation
Every step, from choosing car to the final touches will be documented and published
on this site.
Several videos, many images and fundamental guides will be released under the
ongoing conversion.
My plan is, when finished, to release all videos and images under GNU public
license.