07.05.12

Mazda Laguna Seca Raceway, Monterey CA 07-01-2012

Posted in AC 24, Batteries, DMOC, Design, Drive Train, Gauges, High Voltage System, Lets All Plug In, Low Voltage System, Road Test, Tuning at 10:08 pm by Administrator

EV1E’s Debut as an LiFePo4 powered vehicle proved to be a success. We placed third in the “electric vehicle conversion” division (now ask me how many vehicles were in our division.) Not bad considering I have never driven on a race track. The event was wonderful and enlightening. There were more production cars then conversions. Representatives from Tesla, BMW, Coda, Nissan, as well as the Kleen Speed race team were present. This says something very positive about the future of electric vehicles and hopefully the future of our environment as well.

06.30.12

Yippee! We’re Ready to Go Dad!

Posted in AC 24, Assembly, Batteries, DMOC, Design, Drive Train, Gauges, High Voltage System, Lets All Plug In, Lights, Low Voltage System, Relay Board, Road Test, Seats, Sub Frame at 4:22 pm by Administrator

C'mon lets go!
These are my helpers. They were protesting that I couldn’t take them to Laguna Seca with me. This is an old fashioned “Sit In” They actually slept in the car last night and would not come in (the car was parked in the garage) the house.
We are ready for the big event at Laguna Seca tomorrow. Robert has volunteered his time and car trailer to the cause and we will be loading EV1E on the trailer eeearly in the morning. The Electric Automobile Association California Central Valley Chapter will be represented tomorrow!
I drove EV1E today and she “feels like a different car.” Jack Rickard of EVTV made this statement to me in one of our correspondences about the differences between lead and Lithium. He said when I change from lead to Lithium that my car will “feel like a different car” I wasn’t sure what he meant by it, I mean how could the same car feel completely different? Now I know what he meant EV1E feels more solid more responsive … tighter. Don’t know how else to explain it. Tomorrow is going to be a great way to see just what she can do.

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

Really Getting There

Posted in Assembly, Batteries, Design, Lights, Low Voltage System at 11:48 pm by Administrator

The battery boxes are complete. The Ah gauge has power, The lights work, I am finishing the bottom balancing of the pack. These are the latest pics.

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

06.11.12

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.

06.07.12

Right Idea… Wrong Execution

Posted in Batteries, Design, High Voltage System at 12:55 am by Administrator

So there I was putting together these aquarium looking battery box liners when suddenly they just fell apart. One whole day wasted. So today I did some research and discovered on youtube that there is a better way. I then found some wonderful glue and a tube of another type for about $17.00. I brought them home and within 1 hour I constructed two aquariums. I dropped one of them off at Willy the welders house so he can construct an aluminum frame for them. These will be my two battery boxes for the 14 batteries in the aft section of the car.

05.25.12

Memorial Weekend 2012

Posted in Batteries, Design, Lights, Low Voltage System, Seats at 6:11 pm by Administrator

Last Wed I finally got my seats. I put the passenger seat in the car and it fit almost perfectly. Fortunately I did not drill holes and bolt it in. When I tried to put the seat in the drivers side it did not fit and, will not fit without a major modification to the pan. I was downhearted. In addition, I noticed the shipping company must have set something heavy on the passenger seat. Further, there must have been something which leaked onto the seat and down to the cushion. More on that later. I decided to try fitting the seats out of the little grey Porsche 914 parts car into EV1E. THEY FIT PERFECTLY! They are light and there is only a small mod I have got to make to use them. I ordered the little seat mount brackets from Pelican Parts. Don’t know why I didn’t think of it before.
The bottom balancing continues. I have completed 11 batteries (only 31 to go.) On a “lighter” note…(pun intended) I went to The Ford dealership in Sonora and spoke with the repair guys in the repair and parts dept. They were extremely helpful in identifying all of the wiring in my light switch. One of the gentleman who sports the same name as me-self, even gave me a printout of the pin locations and a diagram of the headlight system. It seems lately everyone is interested in electric transportation and or knows somebody that is building, or converting or owns an electric vehicle. We’ve come a long way getting the word out since 2008 but still have a long way to go. The Ford guys were great and I promised to drive the car up to Sonora and show it to them when I am finished with the new mods. I want to test drive one of the new electric Focus’s. Next week I will be concentrating on the Battery boxes. EV1E is really coming together.
Until next time…
Keep On Pluggin

05.09.12

More Wiring, Component Placement, Door Seals

Posted in AC 24, Body and Fender, DMOC, Design, Drive Train, Low Voltage System, Relay Board at 5:25 pm by Administrator


The big news is the wiring for the motor and the controller is almost complete. It is cleaned up considerably. I have a central buss bar for my ground wires and there really isn’t that much to hooking up relays. I moved the charger to the back firewall (if you can call it that) it is now tucked neatly into the back. Everything looks cleaner. The dash board is also being re-designed…more about that later. I have ordered some more weather pack 3 way connectors. I will install those when they arrive. I have been tripping over stuff in my shop and so as to not be one who dismisses hints from the universe, I am spending the rest of the day cleaning up. Oh one more thing, Rigo from American Glass came over and checked out the EV1E’s doors and windows for leaks. He suggested I add some fiberglass strips to the door frames so the doors can be lined up with the gaskets. I looked at it and decided the aluminum would be a better choice as you can see it turned out pretty nice. I will be re-enforcing all of the doors with aluminum. I enjoy working with aluminum but it is a new concept for me. If anyone can make suggestions as to what tools I need… I have totally fried the grinder wheel on my bench grinder. It appears that a lower speed of everything is used because of the lower melting point temp of aluminum.Cutting is a problem but I find shaping fairly easy, a hand file works well for that.
Well the th th thee Thats all folks!
Keep On Pluggin

05.03.12

Operation Cleanup

Posted in AC 24, Bradley GT II Electrical Diagrams, DMOC, Design, Low Voltage System, Relay Board at 7:54 pm by Administrator

This is the DMOC and wire harness… notice anything different? Where are all the wires? If you follow from the DMOC to the back wall you will see a black cable going into the wall through a gland nut. The new location of the DMOC (controller) has advantages. I moved the relay board into the car on the back wall. Actually I have lost the board and opted for a scheme which allows me to place the relay’s closer to where they will be used.

DMOC Connected to the motor

DMOC Connected to the motor

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