Inside view of the home built controllerOpen controller installed in carController in car, cover on.Close up of controllerWiring
LocationVancouver, British Columbia Canada map
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Vehicle1990 Geo Metro/Sprint (Suzuki Swift clone)
1L 3 Cyl ICE converted to plug in
MotorAdvanced DC 203-06-4001A, 8 Series Wound DC
72-96 volts
DrivetrainManual 5 speed Transmission, clutchless.
ControllerOpen ReVolt Cougar
144V 500Amp Controller built from a kit
from Paul and Sabrina. Previously had a
Kelly KDH12600B
Batteries12, 8.00 Volt, Lead-Acid, Flooded
8V Golf Cart Batteries installed June 2010
System Voltage96 Volts
Home-built. A 1500 Watt lamp dimmer and a
50 Amp bridge rectifier with fuses on both
ends and a 0-10 Amp meter built into a
gutted ATX power supply case.
HeaterCeramic core. (Weak)
DC/DC ConverterKelly
DC/DC 96V TO 12V
InstrumentationKelly SOC Gauge. Digital Ammeter and
Voltmeter. Added an LED bar graph
showing each battery level under load.
Temp guage adapted to measure motor
temperature, Tach activated by magnetic
reed switch and 2 magnets attached to a
disc on the motor tail shaft stub.
Top Speed40 MPH (64 KPH)
AccelerationVery good
Range15 Miles (24 Kilometers)
Driven on hilly terrain. Range is
lower in winter.
EV Miles
Start:138,325 Miles (222,564 Kilometers)
Current:145,671 Miles (234,384 Kilometers)
Total:7,346 Miles (11,819 Kilometers)
    As of 9/12/2019
Seating Capacity4 adults
TiresStock 12"
Conversion Time3+ months
Conversion CostAbout $6500 + 2 sets of batteries.
Additional Features12v Vacuum pump for brakes.
Still running well after 11 years!

code by jerry