Adapter plate dimentionsBooster packMotor&controllerMotor baySticker attached
OwnerDmitry
LocationHillsboro, Oregon United States map
Web/EmailWebPage email image
Vehicle1985 Pontiac Fiero
Low-cost daily commuter.
MotorHyster 9 inch Series Wound DC
ControllerAlltrax Alltrax 72v
Batteries7 Everstart MAXX29, 12.00 Volt, Lead-Acid, Flooded
System Voltage84 Volts
Charger Re-used laptop PSU.
scrap IBM 8A PSU, and couple of diodes to bring voltage down to 14.4v. THE easiest and most robust, yet free setup. Overnight charge typical.
HeaterSeat heater plus 100W window defroster. Plus ceramic heater built instead of core with DUAL POWER - heater is running with thermostat, started by timer, when car is cahrging, so it's warm by my return.
DC/DC Converter IBM laptop power supply
8-9 amps. AUX battery charged at every plugin anyway with main pack
InstrumentationDigital LCD Amp and Volt meters, plus standard analog 12v volt meter for aux battery
Top Speed45 MPH (72 KPH)
45 is doable but pushy. 40 is normal speed.
Accelerationacceptable while on fresh batteries, but lower than normal traffic.
Range13 Miles (20 Kilometers)
untill ovltage under 100A load drops to 10.5v
Watt Hours/Mile350 Wh/Mile
measured out of the wall
EV Miles
Start:159,900 Miles (257,279 Kilometers)
Current:161,200 Miles (259,370 Kilometers)
Total:1,300 Miles (2,091 Kilometers)
 
    As of 6/25/2010
Seating Capacity2 adults
Conversion Time78 hours over 6 weeks
Conversion Cost$300 for donor car and $1000 for all the conversion parts. Got motor at scrap price from forklift. 5 MAXX29 185AH and 2 Costco's 175AH Marine batts. Holding up equally good so far.
Gauges alone were $60, but good instrumentation is a must. Chargers are $90 for 4 of 12A Schumacher - being replaced with CV chargers based on laptop Power supplies.
Additional FeaturesDual power for heater: can run off AC when plugged in, or DC when driving.
Car was built as daily commuter to work through neighborhood roads where 25 MPH is a limit anyway. But also for the sake of building EV - because I am dreaming to buy Aptera, when it becomes available, and while saving $30k for the purchase - I decided to build one myself, while waiting. Definitely a fun project! Got EV built for $1000, and don' have to tear my pickup truck for such a short work commute any more.

Adding range is a question of buying/finding batteries. The most fancy way - get 72V 200AH LeFePo for total cost of $5000 which will give range of 50 miles. If gas hits $6/gal here - this scenario is much possible.

Initially had fork lift 48V controller. Wanted more accceleration, and smootheness.
Dec 2009: Replaced controller with Alltrax 72v (90v max working voltage) and added 3 12v batteries for total of 84V nominal. Battery pack goes over 90v only immediately after charge, that is when controller goes in protected mode. 1kW heater is enough to bring excess voltage down quickly.
It is a whole different driving experience with 84V system!!!
Mar 10: Finally have all 7 batteries brand new: 5 MAXX29 and 2 Costco's Marine. Get 11 miles range, and still at 11v under 100A, 12.2 idle after 30 second rest.

June 10: Finally adding vacuum pump, and my leg got tired. VW-AUDI stock pump from junnkyard is cheap and quiet.

code by jerry