Electric Vehicle Conversion | File037

Ammeter Shunt wiring

voltswagen — Mon, 15 Feb 2010 14:37:16 +0000

Illustration of wiring in a shunt and ammeter.

Shunt + Ammeter wiring

The Winter Chill

voltswagen — Mon, 11 Jan 2010 16:48:53 +0000

It has been so cold lately that all work on the EV in the garage has stopped. Since the garage is unheated and it has been as cold as -20 (yes, minus twenty below zero), it has been way too cold to even think about going outside.
All is not lost. While holed up inside, I have been looking for deals on EV parts and tools online. I did manage to purchase a nice crimper (hammer style) for securing the cable ends to the battery cable. I also have been thinking about batteries. My plans are 48 volts, which I still will do just to keep costs down and it will be enough for my goal of driving around town. But, I think I may design an additional enclosed battery case in the back (between the rear bumper and tranny) to fit an extra three 12-volt batteries. This will give me a couple options if I want to upgrade later and the extra weight in the rear will help with winter traction. Plus, I figure if I plan now I won’t have to deconstruct the whole car later. Since all my EV parts will handle 48-84 volts there is some wiggle room for upgrading. If it warms up I might make it outside to take some measurements.
Stay warm!

Think City Electric Car

voltswagen — Mon, 11 Jan 2010 15:56:13 +0000

A fun video on the Think City electric car.

Hunting for new tires

voltswagen — Fri, 20 Nov 2009 19:30:13 +0000

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.

EV Battery Charger

voltswagen — Fri, 20 Nov 2009 17:17:28 +0000

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

48 Volt SOC Battery Meter

voltswagen — Fri, 20 Nov 2009 16:39:27 +0000

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.

D&D Electric Motor ES-15-6

voltswagen — Fri, 20 Nov 2009 16:28:13 +0000

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

Good day for kayaking

voltswagen — Sun, 08 Nov 2009 16:09:06 +0000

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!

Flip forward VW Beetle front bumper

voltswagen — Sat, 07 Nov 2009 14:49:14 +0000

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

My EV power source

voltswagen — Sat, 07 Nov 2009 14:41:52 +0000

Iowa wind power