Installing MotorFront Battery FrameOperational rear endRight motor mountAdapter Plate AssemblyVacuum Pump and 2nd Battery BoxElectrical StartedCompleted front endRear Springs
OwnerWayne Krauth
Owner's Other EVs2010 Factory Five Mk4 Roadster
2013 Chevrolet Volt
LocationSteep Falls, Maine United States map
Web/EmailWebPage email image
Vehicle1999 Saturn SL2
4 Door Sedan
MotorAdvanced DC ADC FB1-4001 Series Wound DC
9" Single Shaft
Drivetrain5 speed manual with clutch
ControllerCurtis 1321C-7701
120V, 550A
Batteries15 Trojan T890, 8.00 Volt, Lead-Acid, Flooded
190 Ah
System Voltage120 Volts
ChargerZivan NG3
HeaterDC Ceramic 1500W - It helps but wont keep the compartment warm when the outside temp gets down to 10F or less.
DC/DC ConverterZivan DC-DC
InstrumentationOn dashboard: Voltage, Amperage, State of Charge, battery temperatures.
Under the hood: digital voltage meter and vacuum gauge.
Top Speed80 MPH (128 KPH)
and it was still climbing...
AccelerationQuite good from a stop, fair at 40+. It won't win any drag races, but can squawk the tires.
Range45 Miles (72 Kilometers)
Typical commute trips are 34 miles at around 60% DOD.
EV Miles
Start:112,597 Miles (181,168 Kilometers)
Current:120,389 Miles (193,705 Kilometers)
Total:7,792 Miles (12,537 Kilometers)
Seating Capacity4 adults
Curb Weight2,983 Pounds (1,355 Kilograms)
mostly weighed and calculated but slightly estimated
TiresNothing special
Conversion TimeAbout 210 hours. 8 months working nights and weekends.
Conversion CostAbout $11,000, including the vehicle.
Additional FeaturesFun to drive!

$0.85 to charge in the summer
$1.20+ in the winter when using battery heaters and depending on the temperature.

Video of the first drive on May 2, 2009 is: WebPage />
Brief tour of EV components on completed car:
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This EV is also shown on WebPage />
Car sold in Dec 2010. Second EV build started,

Conversion started in Sept 2008 and was completed on May 2, 2009

Jan 2, 2010 - Recently added styrofoam insulation enclosures around the batteries, as the winter weather arrives. Fan ventilation and duct work added to vent charging gasses outside of the garage.

Oct 17,2009 -Drive motor problem. Many thanks to AMD and to KTA Services for providing a replacement. Great customer service!

Steps to do a conversion:
- engine, gas tank & filler, exhaust, radiator, battery, etc removed
- base frames for all batteries fabricated
- assemble DC motor, shaft coupler, flywheel, new clutch, and adapter plate; mounted to transmission
- fabricate right motor mount using both original rubber mounts
- fabricate right drive axle support brace, align and weld to motor mount plate
- 'radiator' battery rack completed and welded in
- 'firewall' battery rack completed and bolted in
- spare tire well in trunk sealed, will be part of the bottom of the battery vapor containment box
- dashboard partially disassembled, removed heater core
- mounted vacuum pump, switch, canister
- gutted center of original heater core to install the ceramic heater
- installed motor controller, dc-dc converter, fuse, breaker, shunts, contactor, relays and potbox on an electrical panel
- completed wiring for: interlocks, all high power cabling (except for battery), control, instrumentation, ignition switch, integration to orig electrical system
- installed heater core and wired to relay
- charger mounted
- clear protective box built for main electrical panel
- replaced rear suspension with stronger springs and struts
- completed wiring new heater and heater fan switch
- front to rear high power wiring in place
- AC inlet completed
- built battery heater control box & mounted in trunk
- re-assembled car body & mounted tires
- re-assembled heater containment
- battery heaters installed and tested
- batteries installed and cabled
- make the belly pan to keep it dry under the hood

Thanks to my fellow EV converters for your advice!

code by jerry