OwnerAndrew Merton
LocationLower Hutt, Wellington New Zealand map
Vehicle1995 BMW 328i/4 SE
MotorAdvanced DC FB1-4001A Series Wound DC
Drivetrain5-speed manual, clutch-less
ControllerCurtis 1231C-8601
Batteries45 Thunder Sky TS-LFP100AHA, 3.20 Volt, Lithium Iron Phosphate
After much brow beating, settled on LiFePo4
instead of Lead, mainly due to weight
System Voltage144 Volts
ChargerZivan NG3
Modified with the addition of the PIC-based
chip replacement board
HeaterBlankets, probably, at least initially!
DC/DC ConverterThermaltake 450W (modified)
InstrumentationStandard, hopefully, but modified to show
useful stuff (amps, volts etc). The E36
electrics shouldn't be too complex for
hacking (the iBus (CAN?) wasn't introduced
until the E46)
Top Speed60 MPH (96 KPH)
This is what I need to avoid irritating
other users on New Zealand's motorways...
AccelerationHopefully there'll be enough
Range30 Miles (48 Kilometers)
Again, this is what I need for my commute,
so if it doesn't get this much, I'll be
EV Miles
Start:205,000 Miles (329,845 Kilometers)
Current:205,000 Miles (329,845 Kilometers)
Total:0 Miles (0 Kilometers)
Seating Capacity4
TiresYokohama 225/50 16" tyres (came with the
car. Might need to go to something with
lower RR...)

Conversion TimeNearly 5 years so far, and still not on the
road :(
Conversion CostCar: NZ$ 4020 ~US$ 2000
Components: NZ$ 7000 ~US$ 3500
Batteries: NZ$ 9000
(so far...)
28-Mar-2009: The car is being handed over tomorrow, but it's
9 hours drive away, so I won't actually get it until we fly
to Auckland in a couple of weeks.

Still clearing the garage...

20-Nov-2009: had the car for a while now; started
removing bits as of about 2 weeks ago. Nearly ready to pull
the actual engine. I'm going to get the AC drained first -
won't be using it for a while, so there's not much point
in needing to be careful about it while the other work is
going on.

13-Apr-2010: Engine out, transmission, motor and clutch
plate are with the engineer for his TLC to get them
connected. Still thinking about batteries; little bits to
still remove (clutch hydraulics, etc); control board
layout to do... The saga continues...

01-Jan-2013: Motor mounted, batteries installed and wired,
controller installed and wired. Only minor changes expected
to the wiring, except the new rules for NZ EV's mean I may
have to completely re-do the under-car high-voltage runs
since they are too close together (min = 150mm separation).

Charger is currently separated from the car - this is to get
around the electrical cert requirement - we'll see if it's

Need to redo the PS - filled it up with ATF, and found a
puddle of it under the car a few days later. Might get the
pros onto it, if it's not too many $$$

Still need a DC-DC - don't think the modified PC power
supply will cut it (PS pump = 40A peak). Might have to try
it anyway.

code by jerry