Finished 120v conversionmotor mountchargergaugesheatercontorl boxtrunk battery boxcoupler
OwnerPatrick Roth
Owner's Other EV2012 Nissan Leaf SL
LocationAustin, Texas US map
Web/EmailWebPage email image
Vehicle1998 Ford ZX2
Very clean one-owner with all the options
and in terrific condition!
MotorAdvanced DC 203-06-4001A Series Wound DC
8" rated up to 4000lbs
Drivetrainfront wheel drive 5spd manual
ControllerCurtis 1221C-7401
400A max current. Doesn't give racetrack
performance, but keeps up with traffic.
Batteries15 Interstate U8VGC, 8.00 Volt, Lead-Acid, Flooded
good deal and local service!
System Voltage120 Volts
ChargerQuick Charge 120v 10amp Select A Charge
low cost alternative from beepscom that
works quite well, batteries are always
within 1/10th of a volt of each other
Heater1500w ceramic with overtemp sensor
DC/DC Converter Cascade audio APS55
55amp continuous at 13.6volts! Works much
better than the original one I had from
Beepscom
Instrumentationammeter, voltmeter, Curtis battery fuel
gauge, motor overtemp warning light
Top Speed70 MPH (112 KPH)
fastest I've had it so far
Accelerationaverage acceleration that won't keep
anyone held up
Range45 Miles (72 Kilometers)
Depends greatly on driving style and
outside temperature. In winter, you may
only get 20miles.. but mild driving in
summer can get you over 45.
Watt Hours/Mile250 Wh/Mile
This is an estimate based on similar
conversions.
EV Miles
Start:146,823 Miles (236,238 Kilometers)
Current:151,296 Miles (243,435 Kilometers)
Total:4,473 Miles (7,197 Kilometers)
 
    As of 2/9/2012
Seating CapacityOriginal seating for four.
Curb Weight3,200 Pounds (1,454 Kilograms)
Weighed on truck scales 1840fr/1360rr
TiresStock
Conversion Timejust over two months
Conversion Cost$2675 donor
$11000 conversion
Additional FeaturesToyota electric Power Steering
Vacuum assisted Power Brakes
Electric heat/defrost
Car equipped with: PW, PL, PM, sunroof, multi CD changer,
tilt, keyless entry, alarm.
9.28.08 I have already begun dismantling ICE
components and hope to have EV parts ordered this week.
10.02.08 All but the engine block out of Motor
compartment, gas tank out! Over 200lbs removed already.
Major components ordered. on my way...
10.03.08 Motor all ready to come out. Driveshafts
removed from tranny. Exhaust out, heat shields, fuel
lines, emission lines. 300lbs removed to date.
10.06.08 Engine came out today! Engine and tranny
separated. Big milestone. 600lbs taken off stock curb
weight.
10.08.08 Tranny has been cleaned and is awaiting
motor. Motor bay has been all cleaned and is awaiting EV
components.
10.09.08 Advanced DC 203 06 4001A motor arrived today.
8 inches
10.15.08 Coupler came back from machinist looking
great. Have ordered aluminum for adapter plate.
10.19.08 Made some battery mockups for trial
placement. Removed clutch master cylinder.
10.21.08 Aluminum for adapter and spacer came today
along with big box of compenents. Made a wood mockup of
the adapter plate just to make sure I have dimensions
right. Fits well and very snug.
10.22.08 Spent about 6 hrs working on adapter and
spacer plate. It all looks good but still have to align
both together with motor running to test for vibrations.
10.23.08 Worked on aligning plates but I have a slight
vibration that needs worked out. I think I know what the
problem is but I need an extra pair of hands to confirm
and fix.
10.25.08 Finished adapter plate and mated dc motor to
tranny. Ready to be installed. Major milestone.
10.26.08 Intalled motor and tranny. Reinstalled
driveshafts, shift linkage, crossmembers.
10.29.08 Working on passenger side motor/drveshaft
mount.
11.3.08 Dropped off motor mount at welder. Cut out
trunk floor for battery rack. Made template for PS pump
bracket. Placed GFI outlet in trunk for charger.
11.04.08 Work on component placement. Test fit
finished motor mount. Work on power port plug.
11.05.08 Prime and paint motor mount. Work on
mounting ammeter and voltmeter.
11.07.08 Spent a couple of days running around getting
parts and finding solutions to heater and ps issues.
Have custom ps pressure line finally. Have everything I
need to install heater and meters.
11.10.08 Work on ceramic heater and power port.
Refill tranny fluid.
11.12.08 Wire heater. Install heater and dash. Move
accessory power port. Run wire for voltmeter.
11.13.08 Cut metal for trunk battery box support and
took to welder. Wired power to volt and ammeter. Ran
load lines for those and Curtis fuel gauge. Fit welded
rear battery box support in trunk. Reinstalled lower
dash.
11.14.08 Installed Curtis fuel guage in instrument
cluster. Reassembled cluster.
11.17.08 Receive batteries, paint rear rack, work on
rear box.
11.18.08 Work on rear battery box.
11.19.08 Work on rear battery box, deliver front
frames to welder, repair and bleed cut brake line.
11.20.08 Finish securing batteries in rear box.
Relocate washer fluid reservoir, work on front racks.
11.21.08 Deliver front most rack to welder. Get steel
for middle rack. Work out 12v heater switch connections.
11.23.08 Wire and place 12v heater switch. Fix cigar
lighter. Explore why horn and power mirrors not working.
11.24.08 Raise rear battery box. Spray foam trunk
openings. Install front most battery rack.
11.25.08 Design and build middle rack over motor with
welder. Cut battery post screws off.
11.26.08 Install custom hood latch support. Paint
middle batt rack. Mount plumb wire mr2 ps pump.
11.27.08 Install middle batt rack. Place final four
batts. Work on batt cable connections.
11.28.08 Secure front batts. Fabricate cables. Connect
all batts.
11.29.08 Mount charger. Run charger wire conduit under
car.
11.30.08 Work on main control wiring, control box.
12.01.08 Add on/off switch to PS. Wire and test PS.
12.03.08 Fabricate lever for breaker. Mount dc/dc and
wire. Install inertia switch. Install charger
interlock. Hook up and test heater; something wrong,
check later. Mount Pot box.
12.04.08 Install heat sink. Connect pot box and
accelerator cable. Connect controller. Take for first
test drive.
12.05.08 Adjust controller to maximum out put. Change
out incorrect charger interlock relay for correct one.
More test drives.
12.11.08 Installed vacuum pump, car finished.
1.3.08 Installed HDPE belly shield.
2.9.09 Replaced 25amp DC converter with Cascade audio
55amp version. Much better.
4.3.09 Installed new electric motor to replace
defective original.
4.5.09 Installed new, heavier rear springs to restore
ride height and quality.
6.11.09 Ran motor overtemp sensor to light on dash.
1.20.10 EV still a wonder to drive with no gas! Has
been totally reliable and a great conversation starter.
4.18.10 OHMer sold to another enthusiastic EVer!
Contemplating next conversion... hmmmmm...

code by jerry