OwnerMac Maunsell
LocationCairns, North Queensland Australia map
Vehicle2003 Proton Jumbuck Ute
Standard Proton Jumbuck ute, vehicle
basically a Mitsubishi Lancer front end,
assembled in Malaysia. Chosen for low
weight, good payload capacity,
aerodynamics, practicality.
MotorAdvanced DC 203-4001 Series Wound DC
Standard ADC 8 inch dual shaft. Brushes
advanced 7 degrees
DrivetrainStandard 5 speed gearbox, clutchless. Use
2nd gear to 80kmhr then shift to 3rd.
Shifting easy, up or down no problem,
fingertip force only. Synchro's in box
make it smooth.
ControllerLogisystems 750 amp
Turned way back to max 300 amps, gentle
ramp. Previous setting (600amps) was a
real tyre shredder, de-tuned in the
interest of
gearbox/drivetrain/tyre/battery life

Update: Swapped out linear for
logarithmic potbox, so much smoother on
takeoff, reversing not so inclined to
launch unexpectedly. All round better
performance. Made up heat exchanger for
water cooled controller - controller is
slightly warm to the touch after 20 km
trip at 100km/h, this is the way to go
for peak controller performance.
Batteries12 Haze Ultimate UL12-100, 12.00 Volt, Lead-Acid, AGM
These are a budget AGM made by Haze
(Germany) in China. So far so good.
Dual auto/threaded post type lugs.
100Ah@c20,63Ah@C1. Good AGM's can
really pack a punch.

Update: These batteries are holding up
really well. I have not had them below
60% DOD, would have at least 100
charge/discharge cycles now.
System Voltage144 Volts
ChargerZivan NG3
Set to single voltage profile, with
custom made shunt type regulation for
each battery. So far pack is staying
perfectly balanced. Gentle profile
should prolong life of pack, charging
takes an additional 20% longer to full
than the 3-step profile. Charger still
pumps the amps in (17amps) up to approx
80% full, then floats off current at
setpoint voltage.

Update: Balancing system working really
well, all cells within 0.05 volts after
resting overnight after fully charging.
Max shunt current 3 amps per battery.
HeaterTropical North Queensland... However
retained air-con to act as window demister
in the steamy hot wet season here.
DC/DC ConverterMeanwell (similar), EV-Power 350 watt
Switch mode power supply set at 14.4
volts, 36 amps max. Charges a 12V 18Ah
sealed battery for usual vehicle loads
(lights, wipers, keyless entry etc.)
InstrumentationTBS E-Meter. Well worth the dollars.
Top Speed90 MPH (144 KPH)
140kmh easily, however amps were getting
up there and road was running out.
100km/hr highway speeds no problem, max
approx 120+kmh with present controller
AccelerationAwesome with higher settings on
controller. 0-100km/hr in under 10
seconds. Now probably 15 seconds as
settings have been tuned down on
controller. Very dependent on battery
state of charge
Range60 Miles (96 Kilometers)
40km driving like a maniac, 80km driving
like Grandpa. Comes down to speed and
terrain. Cant wait for some lithiums...
Watt Hours/Mile60 amps @ 60-70km/hr
100-120 amps @ 100km/hr
Getting better with practice.

Update: Using tacho, ammeter, and gear
selection, once up to speed I can
achieve 1 amp per km/h on flat ground
EV Miles
Start:95,000 Miles (152,855 Kilometers)
Current:96,000 Miles (154,464 Kilometers)
Total:1,000 Miles (1,609 Kilometers)
Seating Capacity2 adults
Curb Weight2,700 Pounds (1,227 Kilograms)
1320kg all up. 200kg heavier than
standard. 370 kg payload. Ute drives so
much better with a bit of weight, too
skittish before. Weight distribution
perfect - 4 batteries over front axles,
8 in rear tray
TiresCrap, getting some good ones shortly.
Lightweight alloy rims. Running at 40 psi
Conversion Time8 months waiting for parts, 3 weeks
evenings and weekends to get it on the
road, BMS etc another couple of weeks part
time. Still tinkering and tweeking...
Conversion CostAU$9500 plus car. Ordered parts ex USA
when Aussie dollar was really good last
October, saved heaps.
Additional FeaturesPower steering (on small 1hp permag DC motor, 3amps@144V),
air-con. Daily driver for 40km commute, 70% at 100km/hr, 30%
city driving. Having a tonneu cover for tray made for
aerodynamic improvement, also plan on installing belly-pan
and blocking off grill. Impact cut-out switch, 12 volt MES
vac pump (ex Sweden) for brakes - super quiet, Andersen
battery disconnect. Liquid cooled motor controller. Huge EV
grin on driver.
Awesome car. My diesel Nissan Navara feels prehistoric to
drive now...


code by jerry