Most of the components...Free Tax!!CarPuter InterfaceNew motor/gearbox ready to install...Motor mount brackets tack-welded...
OwnerMartin Winlow
LocationMuch Hadham, England United Kingdom map
Web/EmailWebPage email image
Vehicle2001 Daihatsu HiJet (aka Piaggio Porter)
Japanese Micro-van, built in Italy
MotorNetgain Impulse 9 Series Wound DC
(www.go-ev.com - NetGain Motors Inc)

Continuous 30HP, peak 100HP
Max RPM 5500'ish.
DrivetrainStock 5-speed manual transmission to rear differential. Ratios (inc 4.44 diff) 1st=16.7, 2nd=9.1, 3rd=6.1, 4th=4.44, 5h=3.7. Clutch-less conversion - this may change once I try it!
UPDATE - 17/7/09 - Despite my reservations, going clutch-less is ok. Just a few seconds delay whilst the gearbox cogs sort themselves out when shifting but I am planning to put the clutch back in soon, simply because it makes the system more flexible when negotiating junctions etc. It will aslo give the van much better acceleration as I'll be able to change gear much more quickly.
ControllerBelktronix 500A
(www.belktronix.com)
Complete system including battery monitors (over & under voltage only - no voltage display or logging - see later for that - one per cell - 38 in my case) and charge balencers, 1.2kW charger/DC-DC converter (50A @ 12.5V), 500A max controller, opto 'pot-box' (throttle control) and associaed gubbins including main contactor.
Batteries38 Thunder Sky LFP160, 3.20 Volt, Lithium-Ion
(www.thunder-sky.com)

Nominal Capacity - 160AH
Operating Voltage - 2.5V to 4.25V
Weight - 5.6kg
Dimensions - 182W x 279H x 71D (mm)

Pack Weight - 215kg
System Voltage120 Volts
ChargerBelktronix (See above)
Is in same box as DC/DC converter. 1.2kW output. (www.belktronix.com)
HeaterWebasto diesel fueled water heater through stock blower unit. (Not yet fited).
DC/DC ConverterBelktronix (See above)
50A @12.8V
InstrumentationCarPuter running Windows Xp with CentraFuse incorporating SatNav, USB FM radio tuner, MP3 player, hands free mobile, home brew VisualBasic based BMS monitoring, warning and data logging program. Plus stock speedo etc.
Top Speed60 MPH (96 KPH)
A bit of a grey area. Using UVE's calculator (WebPage it should do 75MPH (limiting factor being the controller amps) but as I don't have an accurate Cd for the van and a lot of assumptions have been made re batteries, I'll have to suck it and see!

Update 280709 - 55mph but I haven't pushed it yet - still wearing things in.
AccelerationI'm still taking it easy to allow the motor to wear in but still quite peppy starting from 0 in 2nd gear.
Range70 Miles (112 Kilometers)
... at 50MPH, half that at 70MPH - if it goes that fast and about 150 miles at 10 mph!
Watt Hours/Mile300 Wh/Mile
Definitely something best suited to the empirical method of divining but due to the vans poor Cd (little better than a house brick), not good.

Update - 280709 - It draws about 130 (battery) amps at 50MPH (120V pack) This is based on the calulation of volts x amps at the relevant speed (in mph) divide by that speed (see running power consumption calcs lower down).
EV Miles
Start:51,948 Miles (83,584 Kilometers)
Current:53,304 Miles (85,766 Kilometers)
Total:1,356 Miles (2,181 Kilometers)
 
    As of 11/19/2009
Seating Capacity2 adults
Curb Weight2,300 Pounds (1,045 Kilograms)
...before conversion.

- ICE 1300cc alloy engine 107Kg
- fuel tank 11kg
- full tank of petrol 23kg
- cooling system - 11kg
- Bits and Bobs - 7kg
- exhaust/cat 18kg
Total = 177kg
+ motor 57kg
+ batteries and box 240kg
+ electronics 20kg
Total = 317kg - 140kg increase
Post conversion (calculated) = 2640lbs (1200kg). I'm going to try it on a weigh bridge soon.
Tires155R12/88
Conversion TimeTo plan, research and acquire all the bits... about 18 months.

To instal everything bar heater, about 10 x 8 hour days. However, I don't know how long it's going to take to iron out the bugs or 'finish' it. Will it ever be 'finished'?
Conversion CostDon't ask...
Motor - £1200 (imported direct from US)
Combined and matched control electronics, charger-cum-DC/DC converter, system integrator and battery balancing system - £1440
Carputer & battery monitoring hardware - £400
... but the good news is that the electronics should last for 1000k (yes, 1 with 6 zeros after it) miles so they can be moved from one donor to another... that's the theory at least!

At 50MPH it costs around 10p per mile in ellectric which means each time I use the van to do my usual commute, I save arounnd £4 - no servicing costs and no tax and no MOT (something to do with milk floats).
Additional FeaturesElectric 'Fuel' Economy
(wH/mile includes all standby electric costs (warming batteries, carputer), charger inefficiancies and excludes savings from charging at work)
Date ........ kWh . Odometer . wH/mile .. Fuel p/L .. £ saved
220809 .. 44620 ... 52352
310809 .. 44808 ... 52520 ..... 303 ....... 106 ...... 58
181009 .. 45030 ... 53008 ..... 455 ....... 106 ...... 46
151109 .. 45174 ... 53512 ..... 486 ....... 109 ...... 28

(Click on any of the images for a bigger view and notes)

Now running but ironing out a few issues, not the least of which is getting it road taxed (for non-UK readers this is the vehicle excise licence - helps pay to maintain roads etc). This is free in the UK for electric vehicles but first you have to battle G'ment bureaucracy to get it signed off as 'tax class = electric'. DVLA rang last week in response to my application to change its class, saying 'the man' isn't in till Monday (200709). He might have to come out to inspect it...

Update - 280709 - Have to take van to DVLA Borehamwood Local office in 3 weeks for inspection. Meanwhile I have re-taxed it as 'PLG' so I can at least use it.

Update - 030809 - Now done 170-odd miles, still testing and monitoring. A couple of minor issues but all resolved simply. Very pleasant to drive (as long as I'm not in a hurry). Nice and smooth and no engine noise.

Update - 140809 - Meachanical & electric drive systems are fine but having issues with what I think is noise casuing havoc with my USB ports - mostly when charging.

Update - 270809 - DVLA inspection completed - The van is now officially electric! Just waiting on my free tax disc...

Update - 181009 - Free Tax disc arrives but charger dies and EV off road awaiting replacement :( Over 1000 miles done - £120 saved in petrol.

Update - 151109 - Fitted new charger which has twice the output and had the van off the road for a week waiting for it. Can now fully charge within 8 hours with onboard charger. Average UK petrol price now £1.09/l.

code by jerry