Manual Charge ControllerBack SeatMain Disconnect and pack monitorEmpty Battery trays12V Distrubtion and DC-DC ConverterMotor, mount and transmissionOne Battery with chargeSci-FiMain battery Pack
OwnerTom Gralewicz
LocationGreenfield, Wisconsin US map
Email email image
Vehicle1999 Dodge Neon ACR
The factory race version of the Dodge Neon (the ACR) is stripped down - no options and has beefed up suspension and brakes - all the better to carry batteries with!
MotorBaldor M2515 3-Phase AC
Standard industrial 20HP 3 phase 240V motor
Drivetrain2.2L 5 speed manual
Controller Baldor 900 series VFD
Industrial AC motor controller rated at 30HP with a 1 minute peak of 45HP. To start with I will be using a small VFD to generate 240V AC to power the fans and power supply.
Batteries25 C & D Technologies TEL1270, 12.00 Volt, Lead-Acid, AGM
I originally got some 12-270 UPS batteries for free and they drove the design of the car. Recently I got the Telephone batteries, less current, more lift, and they are almost new and only cost $15 each.
System Voltage315 Volts
Charger Individual 12V 10A
One charger per battery. $25 each including shipping from Hong Kong - seller has an e-bay store and gave me a quantity price on 30. Added a swicthed power strip to allow turning on and off each row of batteries - this controls power draw so I don't blow breakers.
Heater120V Ceramic heater rewired for 240V AC (326V DC operation) - not installed yet.
DC/DC ConverterVicor V300A12
Computer DC to DC converter - designed to run on rectified AC input, works fine on a main pack voltage of 300V.
Adjusted for max output 13.2V, rated at 500W (over 40A!) I have yet to draw more than 20A and it runs nice and cool. Its about the size of a thick chocolate bar.
InstrumentationExperimental systems monitor. Microcontroller on the main battery pack to monitor V and A another on on the 12V system. Sending data back to a 7" screen on the dash. Plan to add per battery monitors as well. - Still under construction
Top Speed50 MPH (80 KPH)
Current top speed in 4th gear. I don't want to take it on the freeway until I get better rear suspension, then it 5th gear and go! I got the suspension boosted, now I have synchro problems in the transmission!
AccelerationEstimated 0 to 60 in under 14 seconds
Range50 Miles (80 Kilometers)
The motor controller shuts down below 250V (1.6V per cell) the recommend discharge level for the batteries. I have 2 extra batteries I can plug in as a reserve tank to get me to my destination.
Watt Hours/Mile277 Wh/Mile
Wall to wheels calculation of 1 charge cycle.

EV Miles
Start:119,000 Miles (191,471 Kilometers)
Current:119,300 Miles (191,953 Kilometers)
Total:300 Miles (482 Kilometers)
 
    As of 11/16/2009
Seating Capacity2 adults
Curb Weight4,100 Pounds (1,863 Kilograms)
Originally 2680, subtract the usual parts and add a motor and batteries. These are real car weights with the same driver - A local scrap yard lets me use his truck scale.
TiresStock
Conversion TimeStarted in Summer of 2008. I spent months deciding what car to use and then finding the right one to convert. Current status: Motor is mounted and installed. Battery trays need to be painted and installed. Road tested September 2009
Conversion Cost$1200 for the car (- 300 for parts sold). $750 for the chargers. $450 for the new batteries, $500 or incidentals. The rest has been scrounged for free.
Additional FeaturesFactory Speedometer and odometer working (electronic sensor)
Factory Tachometer showing 3x electric motor speed (its fun to pin the gauge, but I need to divide it down to be a little more reasonable)
Dashboard lights and gauges: Check engine light shows motor controller fault - added fault reset button.
The AC motor has a lower RPM range than the DC motors so I do shift the car when driving.
A group of like minded builders meets twice a month in Milwaukee, WI to work on their cars, help each other out, and find materials. Anyone interested in joining us please e-mail me.

Ben Nelson has shot some videos of the conversion and posted them on youtube, search for "Benjamin Nelson electric car".

Got the car running Labor Day Weekend 2009. Broke the transmission 3 days later :-)


code by jerry