| Owner | Pat Walker | ||||||
|---|---|---|---|---|---|---|---|
| Location | Roberts Creek, British Columbia Canada map | ||||||
| Web/Email | WebPage | ||||||
| Vehicle | 1991 Toyota extended cab pickup | ||||||
| Motor | Advanced DC 9 Series Wound DC dual shaft, rev-limiter magnet and pickup are mounted on the front shaft. | ||||||
| Drivetrain | 5 speed manual transmission with clutch. 1st cuts out at 42 Kmph, 2nd at 72 Kmph. Sometimes use 4th 'cause it's quieter. | ||||||
| Controller | Curtis 1231C mounted on massive aluminum heat sink behind the grill with thermostatic cooling fan. | ||||||
| Batteries | 48 Sinopoly 200, 3.20 Volt, Lithium Iron Phosphate First lead pack did 15,000Kms Second lead pack did 27,000Kms 30 KWH Lithiums installed July 2014 Mini BMS keeps any one cel from over charging. There is a low cel alarm but I try not to go below 50%. During -8 Celsius had to go easy on the throttle below 60% or alarm would sound. | ||||||
| System Voltage | 154 Volts | ||||||
| Charger | Zivan NG3 120VAC at 30A (actually 25A or 15A) On the side of the front battery box. there just isn't room to hide it in the cab. Now set to 10 amps only. That is just fine with me. Easier on the pack, can charge anywhere and with less weight it doesn't need as much juice. Usually shut off by the BMS. | ||||||
| Heater | electric - 1500w (solder all HV push terminals or they will burn)Draws 13amps so if it's on for an hour that is about 2 KWH reducing range from 68 to about 60 miles. | ||||||
| DC/DC Converter | Iota GPC 45 45 amp 144 volt DC-DC converter 2015-11-12 still fine 2012-10-13 New Iota working fine. 2012-09-17 failed after over 4 years 2008-03-08 will be on 24/7, just easier that way. | ||||||
| Instrumentation | e-meter link 10 (always on % now) Mini BMS in and working fine. Had to put in galvanic isolator and re-route cel loop to stop false alarm from PWM interference. | ||||||
| Top Speed | 70 MPH (112 KPH) 2008-04-10 no problem to do 100+ km/h. | ||||||
| Acceleration | just fine, can pull out onto the highway into traffic. | ||||||
| Range | 68 Miles (109 Kilometers) Using trip meter down to 60% then calced to 20%. Lots of hills and no regen so would be better on flat terrain. | ||||||
| Watt Hours/Mile | 256 Wh/Mile | ||||||
| EV Miles |
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| Seating Capacity | 2 normal adults and 3 smaller ones (often 4 normal ones) 2010-10-06 extended cab is used almost every day. People, groceries or farmer's market stuff. | ||||||
| Curb Weight | 3,600 Pounds (1,636 Kilograms) was 4700 with lead 3600 now | ||||||
| Tires | black on rusty rims. Toyo 44psi | ||||||
| Conversion Time | a year and a half. 2016-05-08 8 years 2015-04-04 still having fun 7 years 2014-10-14 still driving 2013-04-02 still driving***5 years*** 2013-01-13 still driving 2012-07-17 still driving 2011-10-12 still driving 2011-01-28 still driving 2010-10-06 still driving 2010-06-22 still driving 2009-10-13 still driving 2009-02-24 still driving 2008-04-07 done. now we drive. 2007-11-28 ordered parts. 2006-10-13 ripped out smelly stuff | ||||||
| Conversion Cost | 2016-09-14 $650 shocks and front end work 2015-09-30 $19 solid state relay for BMS 2015-08-05 $650 curtis repair + main fuse 2015-06-15 $275 new rear bumper (not mounted yet) 2015-02-12 $136 brush ring and springs 2015-02-02 $100 motor brushes. 2014-03-01 $175 reprogram Zivan 2014-01-15 $14,500 lithiums 2013-08-30 $35 used battery. 2013-07-24 charger plug $9 2013-06-09 $40 u-joint 2013-05-04 $35 for used battery. 2013-01-13 $25 battery terminal repair. 2012-09-17 $365 new DC/DC 2012-08-15 $40 15 feet of brake line. 2012-05-10 $45 used motor mount. 2011-09-18 $800 for Curtis repair and shipping, $50 for lawnmower battery. 2010-09-21 $5.00 for new plug, old one starting to go black. 2010-06-20 $750CAD for used Curtis. 2009-12-11 $3,500CAD for new floodies. 2008-04-07 $15,000CAD in parts and batteries the truck was mine. | ||||||
| Additional Features | emergency shutoff cable (works great), inertial cutout(hope it never works), 2 stage rev limiter, motor thermal cutout, clutch in and start position safety, charger interlock (so i don't yank the garage), Mini BMS, ABC fire extinguisher and a really nice pull-out coffee mug holder. | ||||||
| 2019-11-09 Has been sitting in the driveway gathering leaves for two years...motor if fine but controller blew again. Four of the lithium batts are flat but the rest are still at voltage. We are buying a used ev to replace Chuck. Also have an S10 conversion done by canev with good parts including J1772. 2016-09-15 shocks all-round, sway bar ends and stuff make it drive like an MG again. 2016-05-08 DC/DC was clicking and 12v system quit. So I cleaned the old lead aux battery contacts and plugged it in again... went up to 17v and batt started gassing. I ordered another DC/DC from CANEV (great service). Two days later tried a different 12v batt and it worked perfectly. Wish I was rich enough to keep the new DC/DC for a spare. Think the leadie should be replaced with a little lithium, then no more failures and yucky lead contact problems. 2016-02-20 running fine. Mounted inverter under the hood so we have ac power during outages for incubator and brooder lamps. Plan to power the heat tapes under the batteries next winter with it. Should turn on at plus 4 Celsius so I won't hurt the batts by charging below 0. 2015-12-06 Just had a scare.. the charger quit working so I took it out and couldn't find anything obvious so plugged it in on the bench and it started! Um, turned out to be the wall plug for the charge cord, duh. 2015-11-12 Controller shorted and blew the main fuse. Quick to find an fix but time lost waiting for Curtis repair. Solid state relay for the charger was just wired around the screw, burnt off, smoke. So the new one has ring terminals on the wires. We had to drive the gas car while Chuck was down and did not enjoy paying at the pumps. 2015-06-15 Still a pleasure to drive. The turn buckle on the motor hold down opened up so the replacement is welded closed. Back when the truck was down with brush problems the 12v batt drained down so low that nothing worked, the 12v plug in charger wouldn't start so I hit the boost and burned out the isolator on the BMS. Just saying that if you are going to mess with higher voltages on the auxilary batt pull the terminal off... 2015-04-04 Should have replaced the brushes sooner. It was easy and cheap even with fixing the burnt mess. Next time for this build it would be easiest to use a puller to take the brush end off and replace them on a bench. The truck is 24 years old and the rust is starting to nibble at the fenders and under the doors....spent way too much on the lithiums. I need an easy solution like rubber or something. The frame is still fine. 2015-02-14 Had to order a new brush ring 'cause one of the slots was burnt. Such a deal from CANEV..$136 c/w springs ready to go! Got here 3 days after ordering. Had to tap out the terminal screw holes, but brass is easy. Was able to put it all back in from above decks (out of the mud). Cleaned up slots then used a knife stone to smooth the comutator after powering up. The brushes are seating now with 4 12v 12a chargers running. 2015-02-02 Came to a jerky stop after erratic power. Tested here and there and found full voltage to the motor but no joy. Pulled the batteries out of the front box and removed it, about 2 hours.... The top set of brushes had burned right off. Already have a new set($100) and I've ordered new springs. They have only done about 30,000 miles, but might not have been seated before pulling 500 amps and I don't spare the throttle. 2014-10-14 Lithiums in and all the bugs worked out. Goes like stink. Seems to pull about half the amps on hills. Load capacity is 1/2 ton greater and amazing range. 2014-03-08 Zivan is back from reprogramming. I'm cutting out most of the old posts and putting them on the blog: electricchuck.blogspot.ca 2014-01-14 Committed to 48 Sinopoly 200s from Randy at CANEV. He says his mining customers prefer them. And it looks like mini bms, is there such a thing as middle balancing? 2013-12-10 Well, that's it. Lead pack #2 is finished. In the past couple of weeks range has gone from 20 km down to a few. Voltages are consistently low. They don't owe me anything, they've done 4 years and 27,000 km. That works out to less than $20/week or $0.13/km + $0.02 for juice is still about the same as gas. When we started this in '07 lead was the best choice, now... Quitting is not an option. 45 CALB CA180s would be a perfect, a local estimate was $18,500 CAD. I don't want to spend another 4 years dragging an extra 1/2 ton of lead around. And I'll get almost all the truck bed back. The Curtis and the Zivan are still great. Plan to bottom balance and charge to 80% (as Jack R. advises). Don't know about Sinopoly. Will start finding lots of money. | |||||||
1991 Toyota Pickup FOR SALE
“Chuck”
Last Updated 11-09-2019
Copyright © 1997-2024 by Mike Chancey