The Motor is OutThe ControllerInstalling the Electric MotorThe Electric Motor InstalledVacuum PumpInstalling Rear PackFront View Under the Hood
OwnerGregg Witmer
LocationMechanicsburg, Pennsylvania United States map
Web/EmailWebPage email image
Vehicle1996 Saturn SW2
More information on the LiFePO4 pack: WebPage
MotorAzure Dynamics/Solectria AC24 3-phase motor 3-Phase AC
DrivetrainOriginal 5-speed manual trans-axle
Fidanza aluminum flywheel
Factory Clutch

ControllerAzure Dynamics/Solectria DMOC445
Batteries65 CALB/Skyenergy CALB-LFP100AHA, 3.20 Volt, Lithium Iron Phosphate
System Voltage208 Volts
ChargerManzanita Micro PFC20
HeaterCeramic heater core - home built.

DC/DC ConverterIota DLS-220-45
InstrumentationAnalog Amp Meter
Zeva Gas Gauge Driver
Top Speed65 MPH (104 KPH)
Accelerationacceleration is acceptable -- but, not quite what the ICE
version was.
Range75 Miles (120 Kilometers)
Watt Hours/Mile260 Wh/Mile
This takes charging into consideration -- wall to wheel.
EV Miles
Start:128,650 Miles (206,997 Kilometers)
Current:129,123 Miles (207,758 Kilometers)
Total:473 Miles (761 Kilometers)
    As of 7/7/2011
Seating Capacity2 + 2 adults
Curb Weight2,700 Pounds (1,227 Kilograms)
Conversion TimeStart to finish was about 2 years. Obviously, I didn't work on
it everyday. In reality, there are many odds and ends that
need to be done, so even after 2 years, this project is not
Conversion CostI have to keep this a secret because if my wife finds out she
will kill me and now that the lead has been replaced with
lithium, she will kill me again.
Additional FeaturesThe lead based aux.12v battery has been replaced with 4-10Ah Headway batteries. Very
small and light way to replace the aux battery.
The motor, controller, adaptor plate, hub and several other minor items were
by Electro Automotive.

Sealed Lead Acid comments from 2010...
Still not happy with the range and the performance. Took the pack voltage from 144 to
168 and got a reasonable improvement -- however, I may take it up to 192 to see what

CALB comments from 2011...
Very happy with the range, performance, drivability and efficiency with the CALB Lithium
batteries and the Manzanita charger.

code by jerry