Sunshine and Green Power SourceMachined Flywheel on Azure AC24LS MotorTransmission, Rear Suspension and Motor Azure Dynamics DMOC ControllerNew charging portCharging at the library
OwnerJack Marshall
LocationLos Gatos, California United States map
Vehicle1974 Porsche 914
MotorAzure Dynamics/Solectria AC24LS 3-Phase AC
DrivetrainI used the stock clutch and five speed
transaxle, but I had problems with vibrations
around 4500 rpm. So I got the flywheel
machined down from its original 17 lbs. to
about 11 lbs., shortened the motor shaft and
spacer ring by about 5/8" and had everything
really well balanced. This completely
eliminated the problems. Now I get best
efficiency at 45 mph in 2nd gear - a bit over
5000 rpm. (Many thanks to Mike Brown, "Mr.
Electro Automotive".)
ControllerAzure Dynamics/Solectria DMOC445
This controller is a really nice design, but
it's tough to make any sophisticated
electronics reliable in a vehicle. Now that
Azure is out of business I've had the thing
opened up several times on the workbench. I
replaced the connectors on a particularly
troublesome ribbon cable and everything seems
to work fine now.
Batteries18 US Battery 8VGC HC - XC, 8.00 Volt, Lead-Acid, Flooded
System Voltage144 Volts
ChargerElcon PFC-2500
A standard J1772 charging connector is mounted
on the right side of the front bumper. A
Modular EV Power AVC2 vehicle control module
and 110/240 VAC compliant charging electronics
are used so charging works fine from 120 VAC
at home or up to 240 VAC from a commercial
charging station. The PFC-2500 provides 1500W
at 120VAC input or 2500W at 220VAC.
HeaterI used a pair of travel-size hair dryers
connected into the original heating ducts.
They're switched using a beefy DC relay
controlled by the original heater switch on
the floor. I hooked them up in parallel and
set their switches to "low" and this works
fine from the 144V main battery.
DC/DC ConverterElcon TDC 144 14 EGC
InstrumentationAmmeter (+300/-150A), SOC Gauge, 12V system
voltmeter. The original tachometer, alternator
light and oil pressure light are driven from the
Azure Dynamics controller.
Top Speed70 MPH (112 KPH)
This was on flat road with nearly a full charge.
AccelerationThe acceleration isn't anything to write home
about - zero to sixty is over 20 seconds.
Range45 Miles (72 Kilometers)
This is typical range at 35 to 45 mph on a warm
day with some red lights and only moderate
accelerations. I try to drive fewer than 40
miles on a charge. Any farther and the
performance really suffers.
Watt Hours/Mile400 Wh/Mile
This is the typical wall socket to odometer
efficiency at 35 to 45 mph on a warm day. It's a
strong function of driving style and I've seen
it as low as 285 Whr/mi driving like granny or
as high as 500 Whr/mi out for a joyride.
EV Miles
Start:91,234 Miles (146,795 Kilometers)
Current:102,820 Miles (165,437 Kilometers)
Total:11,586 Miles (18,641 Kilometers)
Seating CapacityTwo adults or driver plus guitar.
Curb Weight3,000 Pounds (1,363 Kilograms)
Preconversion curb weight was 2100 lbs. and 3000
lbs is a best guess.
TiresContinental PureContact 195/65R15 at 45 psi.
Conversion TimeTotal duration 2 1/2 years -- actually about a
year of weekends, and then another year of
tweaking. (And still making refinements all the
time...)
Conversion CostAbout $18,500 plus the cost of some
transmission, steering and suspension repairs.
Additional Features- Electric windshield washer pump (from a 911) in place of the
original spare tire pressurized washer.
- New hood shocks in front and rear from Camp 914.
- New fuse panel with blade fuses from J-West Engineering.
I used the Electro Automotive AC VoltsPorsche kit and tried not to
add anything too modern looking. Sunshine still has that sweet 1970's
look and feel.

Milestones:
11 April 2010 - completed in time for the 40th Earth Day
13 June 2011 - passed the "1,000 EV Miles" mark
3 March 2012 - 5,000 EV Miles
6 November 2013 - First charging at work
3 February 2014 - Upgraded to PFC-2500 charger - 4 1/2 hour charging
at work.
11 March 2014 - 10,000 EV Miles
23 May 2015 - Sold to another EV conversion enthusiast!

code by jerry