Archive for November, 2009
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20
Nov
2009
Hunting for new tires
Where to find used tires
I will be hitting the Grab and Go Auto Salvage this weekend looking for some rear wheels for the Beetle. This summer I passed up some near new Goodyear Wrangler tires that were on a Chevy Blazer (at the time I had a Chevy Blazer and was thinking of buying them) the cost for the 4 tires would have been $48 dollars! Having once purchased Wrangler tires for a Jeep (and actually worked designed Goodyear advertising for awhile) I know those tires would have been $125 a piece. Yes, I am still kicking myself for not buying them this summer… maybe they are still there? How sweet would that be. They probably aren’t the best choice for an EV, but they sure would look cool on the Beetle.
20
Nov
2009
EV Battery Charger
So here is my battery charger for my battery pack. I am going to be using a Minn Kota MK440 battery charger for my main pack. This charger is a 4 bank charger and will supply 10 amps to each battery. The 440 is a multi-stage charger (3 stage) so it does bulk charging until the battery reaches 75% then goes to absorption mode and finally goes to maintenance mode (float). This charger also has temperature compensation which I guess adjusts the voltage so the battery reaches the gassing threshold depending on whether it is cold or warm outside. Higher in cold and lower in hot temperatures. The charger weighs 22.5 lbs.
This charger retails for $379. I got my new one off ebay for $225.95 shipped. That link should bring you to the search listing on ebay.
So why the Minn Kota charger? Couple reasons. First the front of my Beetle is a fiberglass front that isn’t totally sealed. This charger is water-proof, since it is a marine charger and should work well for my application. Second, I figured that if I outgrow it (i.e. add a larger battery pack), it will be perfect to put in my mother’s pontoon.
It fits perfect next to the batteries in the front (my main pack). The accessory battery for lights, taillights, etc… will be under the rear seat (normal location on a stock Beetle). The batteries in the photos below are ones I collected from friends to use as cores. They are all group 31 size approximately 68lbs each. With the battery charger the front is getting heavy… 302 lbs (280lbs of batteries and 22 lbs for the charger).
Minn Kota MK440 battery charger
Front battery rack for the EV
Access to the charger
Just enough clearance
20
Nov
2009
48 Volt SOC Battery Meter
Got my SOC (state of charge) battery meter the other day. It is a 48 volt golf cart meter. The empty marking is 20%. This was a new old stock part I got off ebay for $10 bucks shipped (the guy had only one, but there were other similar ones and a cool illuminated one). My “plain Jane” meter doesn’t have a light so I’m thinking of adding a couple LEDs above the speedometer and gauges of the bug. There is a small lip where I should be able to fit 3 L.E.D.s had have them shine down on the gauges.
48 Volt battery meter for the electric car.
20
Nov
2009
D&D Electric Motor ES-15-6
I’ve had my electric motor for quite awhile and just realized I hadn’t posted anything about it. I haven’t done much with it yet except for fitting and measuring.
Here are the motor specs:
D&D electric motor, model ES-15-6 DC – 48-72 volts – 10 HP cont, 40HP peak
Not sure of the actual weight but I would guess around 60lbs. Measures 6.7″ Dia x 12.28″ Long
It has a 7/8″ single-shaft (although the back of the motor does have a removable cover plate covering the shaft – might to rig a tach to it).
It has front mounting holes and a base plate.
Purchased mine used off ebay.
Electric motor #ES-15-6 shown with my Gates pulley
8
Nov
2009
Good day for kayaking
Had beautiful weather and headed out to the local state park for kayaking. We have 2 of the Old Town Twin Otter kayaks and are perfect for our family. Super stable, easy to get in and out and so far haven’t dumped them when the kids decide they need to stand up!
7
Nov
2009
Flip forward VW Beetle front bumper
I didn’t have a front bumper and saw this flip forward bumper at JC Whitney… first thing don’t buy parts at JC Whitney! This bumper isn’t that bad, but it take a lot of time to mount and adjust.
I put a coat of POR 15 rust preventor on it first then roughed it up, primed and painted a satin black. It turned out OK.
Primed
Final paint
7
Nov
2009
My EV power source
Iowa wind power
7
Nov
2009
Adapter building – EV conversion
Like others I am disassembling the clutch disk, so I can have something to fit the splined shaft of the transmission.
Here is the before.
Electric car adapter/coupler building
Just grind off a few pins and it will pop apart.
Clutch disk apart
I have a second clutch disk as a back-up. It is slightly different, but this one seemed to fit the shaft very good. I will update as I get more parts for the adapter.
7
Nov
2009
Get a working vehicle for an EV conversion.
My original plan was to purchase a working, running VW Beetle to convert to electric. Saw this project and thought perfect.
Save some time and get a working vehicle so you know what you have!
7
Nov
2009
Re-indexing “Lowering” VW Beetle
The previous owner had raised the rear of the beetle for 31″ tires. At first I thought maybe there was something rusted together, because it was so stiff. Now, I know that they just didn’t know what they were doing. There are tons of VW Beetle service manuals that tell you how to lower/raise the rear end. I found 4 videos on YouTube that provided me with enough info to get the job done and only took about an hour (not including the time to remove rusted/broken bolts!).
Here is the video link:
My spring plate bolts were rusted on and then of course I broke some of them. A lot of Liquid Wrench, heat and repeating and they came right off!
Trying to remove broken, rusted bolts