Wow!

I'm so impressed with automotive engineering. I've been half the day removing I don't know what all. Lines and brackets and shields and every kind of widget and gizmo. I would be awe struck by any mechanic who could ID all the stuff on my garage floor. Thank heavens the electric version will be SO much simpler!

Previous project balance $5505
Credit for substitute item -$150

New Balance $5355

Why Wait For Detroit?

Indeed! I am sure gas will go back up. You can drive an e-car for the equivalent of slightly over a buck a gallon. Think of it; no oil or filter changes, no fuel filter changes, or air cleaner changes, or belts, or hoses, or coolant changes, no tune-ups, no "check engine" lights, or oxygen sensors, catalytic converters, mufflers, tail pipes, drips on your driveway. Did I mention dependence on somebody else's oil? Do it.

Who Killed The Electric Car?

Nobody can! When folks are passionate about reducing Greenhouse Gases, shrinking their Carbon Footprint and adhering to the RECYCLE triangle of Reduce, Reuse, Recycle, this effort won't be stopped.

Decisions, Decisions!

For help choosing components I joined the Fox Valley Electric Auto Association. There are lots of electric car clubs. This one dedicated to promoting e-cars and supporting it's members in building and owning EVs, has interesting members, informative meetings and newsletters and fun events. It is located in (what else?) the Fox Valley west of Chicago.

Also available on-line is the Electric Vehicle Discussion List with loads of very knowledgeable contributors.

The suppliers I used also sell "how to" books, tapes and CDs and offer engineering and design consultation. They will give no charge advice on products they sell. Their sites also feature conversion packages or kits that list components suitable for cars/trucks of various weights and driving expectations (speed, range).

Though not listed as links, these sites (and many more) are easy to get to.

Fox Valley Electric Auto Association (FVEAA)
Electric Vehicle (EV) Discussion List
KTA Services
EV Parts
Cloud Electric

More Parts & Pieces

Having decided on an operating voltage of 120V for the battery pack I can now order (I mean have ordered) a Battery Charger and a DC-DC Converter. The charger will refresh the entire pack at one time. The converter, drawing from the main pack will provide 12 volts for auxiliary equipment such as lights, wipers, fan motor and of course radio, taking the place of an alternator.

Russco charger
No name converter
Batteries for the main pack could be:

20 - 6V batteries
15 - 8V batteries
12.5 - 9.6V batteries (just kidding, no such animal) or
10 - 12V batteries

My choice will be determined by the available space for placement and
weight distribution.

New parts order $948
Current project TOTAL $5505

An Impressive Pile

This is quite a heap of greasy, dripping, high maintenance junk! Hopefully on the way is my order of clean, new, low or no maintenance parts. Still to come out are the fuel tank, fuel pump, filler tube and rear seat. Then, out of curriosity, I will get her on the scales before I start adding components.

A Satisfying Moment!

Remove hood and place front of car on car jacks. Disconnect air intake, exhaust manifold, fuel line and filter, radiator hoses, heater hoses, A/C system belts and hoses, alternator, starter, wiring harness where attached to engine, anything else attached to engine (except an engine hoist). After loosening the bell housing bolts and engine mount bolts, take a strain on engine and remove the loosened bolts. At this point I found I needed to remove the pulleys from the outboard end of the engine for clearance. Find a helper (thanks to my son Dan) and pull the engine!

Parts Ordered/Cost Update

Ordered:

Advanced DC Motor L91-4003
Curtis Controller 1221C-7401 w/potbox
Albright Contactor SW200B-3-12
Ferraz Fuse 400A/150V
GE Circuit Breaker 200A w/ switchplate
KTA Brake Vacume System
CEV PTC Heater Core
Various switches, barrier strips, 3 meters, shunts
bracket for meters, battery heater pads, etc.
(this assumes 120V, 400A operating system)

Total order $3743

Project total to date Car $400
Transport of car $383
New wheel covers $31
Parts order $3743

Current Project TOTAL $4557

Yikes!

It's ZERO in the frozen tundra today! No workee. Also the suppliers I've sampled are low on shelf parts. As if I needed an excuse to delay work.

To Begin

The first thing is to get some baseline info. She tips the scales at 2101 lbs. and stands 8" off the pavement in the front and 10 5/8" in the rear. Next, before I get to thinking Edna's too cute to chop up, is disconnect the battery and drain the fluids. Shown is the engine compartment - before;

And The Smoking End

She smokes - a lot. This view begs the old question "Would you still drive your ICE car if the tailpipe came out of the steering wheel?"

Thanks for the Help

Thanks to sister Sal for the loan of her excellent tow vehicle.

Thanks to my wife Ellie for sharing the driving to Lititz, Pa. and back with "Edna" even through the white-out blizzard on Mi.'s I-75. Cost - $383

I Have One!

I am the winning (lone) bidder on a '97 Hyundai Accent with a warped head! $399.99 was the ebay low reserve so I lavishly bid $400.00. Race enthusiast Ryan the owner tells me her name is "Edna", that she doesn't mind being referred to as a clown car, but isn't willing to head for the landfill anytime soon.

You'll Need A Donor

Although many other vehicles have been converted, following is my list of small, lightweight, stick shift cars I consider suitable and within my reach. Of course one of these, on further investigation, might be found to be too old, too new or otherwise unfit;

• BMW - 2002


• Chevy - Aveo, Geo, Tracker


• Daewoo - Lanos


• Dodge - Neon, Omni


• Ford - Festiva, Fiesta, Focus


• Geo - Metro, Storm, Tracker


• Honda - CRX, Civic, Fit


• Hyundai - Excel, Accent


• Plymouth - Horizon, tiny pickup?


• Subaru - Justy


• Suzuki - Swift


• Toyota - Echo, Tercel, Yaris


• VW - Rabbit, Golf, Beetle, Carman Ghia


• Yugo - GL


• or similar ...

Who Might Want One?

A mechanic, someone who likes car maintenance, someone who HATES car maintenance, an electrical/electronic enthusiast, a gadgetrist like myself who needs a project, someone who has been 'sent to the garage', an environmentalist, some other kind of 'mentalist'?

My EV Project

I hope to use this blog to show progress and costs of converting an ICE (internal combustion engine) car to an electric vehicle.