12.08.12

The Zivan Returns

Posted in Charger at 6:32 pm by Administrator

Last week I told you about the on going issues with my charger. This week I got it back and immediately installed it into the car. Then I tested it, the fans did not come on. I called ELCON and spoke with Rick, he told me to check and make sure the IC chip was fully seated. To do this I had to uninstall the charger and remove the cover of the Zivan… when I did I saw that the chip was not fully seated and I pressed it back into the circuit board. This time when I tested it the fans came on. Simple. I let it charge my pack until it shut off. The measured voltage was 142.2 volts.Better then the 140.6 volts it was set at, but not the 148 Volts I requested. I called Rick back and he had me do a quick tweek on the charger and viola! 148 Volts perfecto!

11.30.12

New Voltage for an Old Zivan

Posted in Charger, Tuning at 7:51 pm by Administrator

I spoke with Mark at Elcon yesterday and he said my charger is ready and has been reconfigured to 148V. They couldn’t do anything about the amperage. NEWS Watch For The New Porsche Blog!!!

11.03.12

OUI MADE THE RUN

Posted in Batteries, Drive Train, Road Test, Wipers at 7:07 pm by Administrator

I am writing this post from Jamestown, CA. It is Saturday and I… OUI… EVIE and myself, arrived unscathed and without the aid of a flatbed tow truck in Jamestown this afternoon. I left Delhi with 196Ah to attempt a 60mi uphill drive. Oui arrived in Jamestown at 1715hrs PDT with 103.9Ah left in the batteries. Did I mention uphill thats right, there is a 1329ft difference in elevation between my house (elev. 118ft) and Jamestown (elev. 1447ft.) Of course I drove conservatively but I did have my headlights on for the last 15mi. So the way I figure…
196Ah-103.9Ah/60mi=1.535Ah/mi. How did the car perform? I am experiencing vibration and I can’t tell if its the road or the car. The car was able to go 40mi/hr on some of the steeper climbs. This car may not be fast but she climbs like an elevator. This is only the beginning. Yesterday I hooked up my windshield wipers so that they park. They park on the opposite side I had them on so I had to heat them up to orange and bend them the opposite direction and temper the arms in cold H2O so they still have some spring. They look, and more importantly, function great. I am getting the garage ready to bring Otto home from Cars Etc with a new paint job. I have plenty of fresh ideas inspired by my conversing with the folks at EVCCON and Richard at ReFuel. That will be my wintertime project. Now its all about EVIE… Oh and my 50CAL BBM but thats another story.
“Keep On Pluggin”

07.28.12

Keep On Pluggin

Posted in Accessories, Gauges, Heater, Lights, Low Voltage System, Road Test, Tuning at 6:37 pm by Administrator

I received my GPS Speedometer from Speedhut. It sure is pretty. I am almost ready to embark on the long ride uphill from Delhi CA to Sonora CA. I only need to finish bottom balancing twenty more cells and then I can charge to a much higher capacity then I have been. In the meantime I am finishing the design of the interior and the process of sealing EVIE up for those colder wetter days. I also received my contactor for my heater which I designed last year. Lots to do and little time to do it. I just keep on pluggin away at it little by little. I am embarking on a new green business soon… watch this blog for further details… I can only say this… It involves Green devices, EV’s, Fairness, Public awareness, and Earthly preparedness. Thats all for now. I will let you know how the Central Valley to Foothills run goes.
If you have any questions or want to make a comment, feel free!
Keep On Pluggin

06.28.12

Long Week, 121 Gigawatts! what was thinking!

Posted in AC 24, Accessories, Assembly, Batteries, DMOC, High Voltage System, Low Voltage System, Relay Board, Road Test, Seats at 10:49 pm by Administrator

Ok here is the scoop. Today, The Day on the calendar wherein, in 1955 Marty McFly first went back to the future in Doc’s Delorean, EV1E received her first jolt of Lithium Power. A very historic day.
As I said it was a long week. I took Monday off thanks to the graciousness and understanding of my fabulous program manager. So what did I do with it? I finished wiring the Low Voltage system. I tested all the relays and made sure they all functioned properly. I re-read the instruction manual for my PL6 which is supposed to be able to discharge a battery at 40Amps. I went through all of the steps and the only thing I got was a message that said “Bad Cell Count” and no matter what I do that is all I can get. I called Revo and sent several emails but alas a good product is only as good as the support behind it. Given that rule I have to say that the PL6 is a bad product… only because of the lack of support, that and it wont do anything useful. Did I mention I called them… this started about three weeks ago and I have yet to hear from them.
That said and done I had to figure another way to balance my pack. This took some thought…
On Tuesday I hooked up the DC to DC converter and Willie the welder came over and we welded the new seat brackets in so that I could use the 914 seats… The seats were too high, 914 seats too high! We revisited the old bradley seats and made some modifications to them and that is what I am using. On Tuesday I we also put in the locking mechanism for the aft battery boxes. On Tues night I Started placing batteries in the boxes in the proper configuration. I also fitted the connecting cables which connect the front box to the aft boxes. Wed I spent most of the day trying to configure the PL6 to discharge more then 7.99Amps. Then Willie came over again and he took the seat brackets out so that the Old Bradley seats would fit. I also pulled the three point seatbelt system out of the Porsche 914 and installed it in EV1E. I used the roll bar for the harness attachment and the other two points are where I had the lap belt. Today was great! I decided I was going to hook up all of the main pack and check all the systems. They are working. I drove the car down the block and thought this car is sluggish… I drove back home and parked EV1E in the garage and went to apply the E Brake, it was already applied. I took off the E Brake and drove to the end of the block again this time with much more pep.
About balancing. I am going to charge the pack until the most charged battery reach’s 3.5 volts then, I am going to measure the lowest voltages and take the high voltage batts out of the string and charge everything up to 3.5Volts. Then reintroduce the charged batts which were removed and have a balanced pack. I can then run the car normally until the batteries are discharged to almost 2.75V then I can hand balance them. For Now I have just a little more to do and I am ready for Laguna Seca.

06.23.12

OK Say’s Autopilot

Posted in AC 24, Accessories, Assembly, Batteries, DMOC, Design, Drive Train, Gauges, High Voltage System, Low Voltage System, Relay Board at 6:32 pm by Administrator

I have connected 4 batteries in parallel and am bottom balancing them all at the same time. Since I have to be away for a few days I thought I would Let the machines take over and when I called to check up on it I was told that they had already finished… I guess I will see soon enough, but if that is the case I will be able to do these much faster. Only a few days left and all I have to do is finish bottom balancing, hook up the main pack, hook up the DC to DC converter, weld in the seat brackets, seat belts and shoulder harnesses, adjust rear brakes, and hook up the instrumentation. Piece of cake! (gulp) Then I have to charge the pack and I will be ready to roll.

06.21.12

More Wiring, Wiring, Soldering Wires, and Wiring

Posted in Accessories, Assembly, Batteries, Design, Lights, Low Voltage System at 12:12 am by Administrator


The light switch is installed and works properly. I was able to use the directional light switch I purchased in 2009 (and wasn’t able to use) which now functions as the turn switch and hi beam low beam switch. Ahh time and good ol book learnin are sure wonderful and useful tools. The directional lights, brake lights, headlights (Hi and low beam), and taillights are all hooked up and functioning properly.
The Batteries fit in the front in three rows of nine each just like little soldiers. I used two 3/4″ gland nuts to run the battery cables through the firewall. They will connect the front pack to the two rear packs. As I write this I am falling asleep so I think I better hit the hay.
Keep on Pluggin

06.16.12

Wiring, Correcting, and Porsche Seat Brackets

Posted in Accessories, Batteries, Heater, Lights, Low Voltage System, Seats at 5:55 pm by Administrator


Hello friends and neighbors, Today we will talk about the cost of errors both in materials and precious time. If you have been keeping up you remember I short changed one of the battery boxes. I am proud to say that this error has been corrected but it took a good hour or so to measure, cut, and glue together the new lexan box. Then Willie the Welder needed to modify his aluminum frames. We only need to add on 3″ to the existing structure. Sounds simple right? Simple if rebuilding half of the battery frame is “simple”. More time… tick tick tick… So what was productive? I figured out the headlight switch and wired the tail lights. I constructed GM style weatherproof connectors for the right and left taillights, headlights, directional lights, potentiometer, and the front and rear wire harness, I also hooked up the ignition switch so that it activates the fuse block. Lots of soldering. What is next? The Porsche 914 seats and brackets, the finishing up of the lighting system, Installing the batteries, Hooking up the DMOC to the DC to DC converter, a maintenance switch, adjust rear brakes, finish bottom balancing, charge and test. Oh I almost forgot… I need to redesign the dash panel. I am going to wait until the ReFuel event is over before I connect my heater. Probably wont need one anyway, its been very hot in California. Only two weeks left tick tick tick…

06.11.12

Just a Little Short On One End

Posted in AC 24, Accessories, Batteries, Body and Fender, Bradley GT II Electrical Diagrams, DMOC, Design, High Voltage System, Sub Frame at 11:33 am by Administrator

While I was perusing the website I noticed that for some reason I got it in my head that I would only need 7 cells on each side in the back. I can only fit 27 cells in the front rack. A quick calculation and I come up with 41 Batteries total. So we (Willie the Welder and I) are putting 8 batteries in the back on the drivers side and 7 on the passenger side giving us a total of 15 batteries in the back approx 180lbs plus the 130lbs of motor and the 40 or so lbs of Controller and the 9 lbs DC to DC converter approx 350lbs in the back and 324lbs in the front. Let me see…
Thats 684 lbs say 700 lbs which includes the motor, controller, dc to dc converter, charger and all of the batteries and battery boxes. the body with the windows and accessories weighs in at 600lbs and I dont know what a 74 VW chassis weighs so I am up to 1300lbs not including the weight of the chassis. Does anyone out there know the weight of a 74 VW chassis? The weight of the Lead acid gel batteries I am replacing was 840 lbs and only 1/3rd the energy. I think this car will weigh in at approx 2100lbs fully energized.


These photos show the passenger side battery box with the batteries in it (not final) to show how they will fit in the box. Obviously they are not ready to be hooked up. Note the pos and neg terminal placement…not correct. The second pic shows the bat box placement in relationship with the controller.

04.27.12

Re Wire with Heat

Posted in Batteries, Bradley GT II Electrical Diagrams, Design, Gauges, Heater, Lights, Low Voltage System, Wipers at 4:36 pm by Administrator

Ok guys I finally got the heater installed properly and the plenum is in place. The wire harness is installed and anchored in several places. The wires are all labeled and I even found the schematic. I guess I didn’t give it away after all. So onward and upward. I ordered a harness weather kit and when It arrives I will make new connectors for the modified headlight and directional light system. Today I received my PowerLab 6 in the mail and will start bottom balancing my cells while I am working on the wiring. Today of course, I am at work so the balancing act will have to wait until later.


And so I plan… Three battery boxes built for easy access and durability as well as strength. Here is my plan. A lexan box with an aluminum frame riveted to the outside of it. The frame will be built from Aluminum L brackets. My neighbor Willie can weld aluminum so the brackets will be welded. With this setup you will be able to see the batteries and they will be protected. The design is light weight Aesthetically pleasing and durable (have you ever tried to break Lexan?)
I see three arrays of batteries. Two with eight cells each on either side of the motor and one big 26 cell module up front. the most pos and most neg terminals in the pack will be at the very back where they can be easily connected to the controller.
Then there is the speedometer, I have been looking at GPS speedometers and think I have found one suitable for my needs. I found it at the Speedhut
It is very cool and does not require anything additional to work. It comes with everything.
Next on the list is my interior… But that is another story
Keep On Pluggin

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