|Location||Seattle, Washington US map|
|Vehicle||1994 Honda Del Sol Si |
The Honda Civic Del Sol is a 2-seater front-engined, front wheel
drive, targa top convertible manufactured by Honda in the 1990s.
Production and sales ran from 1994 through 1997 in the U.S. with a
total of slightly fewer than 75,000 models sold in America.
|Motor||HPEVS AC-50 3-Phase AC|
|Drivetrain||1.6 liter SOHC 16-valve four cylinder D16Z6 1.6L 125 hp (93 kW) I4 |
engine with Honda's VTEC. 5 speed manual transmission.
96V nominal 130V max input
650A max current output
|Batteries||36 CALB/Skyenergy SE130AHA, 3.20 Volt, Lithium Iron Phosphate|
|System Voltage||115 Volts|
|Charger||Elcon PFC 2500|
120/230 VAC Charger
Charge Profile 611 charging to constant voltage of 3.45 V per cell.
|Heater||DBK 1500W PTC heater|
Replaced old heater core (what a pain tearing out the entire interior
and dash!) with ceramic heater core. Using existing AC button
circuit to turn on heater. Heater element is on only when AC button
is depressed and the fan is on.
|DC/DC Converter|| IpDCIS-9612|
CleanPower (looks the same as Chennic) 400W DC-DC converter
2 DC-DC converters. One always on and the other on with key
switch in on position.
|Instrumentation||ZEVA II Fuel Gauge Driver Plus|
Existing tachometer displays 100s of amps and existing fuel gauge
|Top Speed||100 MPH (160 KPH)|
Fastest I've been on the highway is 80 MPH. It felt good at that
speed and I think there is enough power left to get over 100. Not
very far over but I think a little over.
|Acceleration||not yet tested|
|Range||65 Miles (104 Kilometers)|
Real world urban driving with hills, traffic, stop & go, the whole
enchilada. Farthest drive to date was just over 65 miles and that
brought by average cell voltage to 3.17 V. Still have some juice left.
Also have done a couple 65 mile highway trips. The car has no
trouble cruising for over an hour at highway speeds. Motor and
controller temp never climbed above 45C.
|Watt Hours/Mile||250 Wh/Mile |
Based on my typical Seattle winter driving. In city with some
freeway and plenty of hills. Also full-time headlights, some wipers,
and some heat. This should be my worst case scenario.
|Seating Capacity||2 adults|
|Curb Weight||2,512 Pounds (1,141 Kilograms)|
Original Del Sol Si curb weight: 2414 lbs
+98 lbs for conversion!
GVWR 2975 lbs: still have a 463 lb payload capacity!
|Conversion Time||6 months|
$17,000 + $3000 for donor vehicle
|Additional Features||Three of the original motor mounts attached to the transmission and were reused. I designed a |
custom 2 piece aluminum motor mount for the free end of the motor that attached to an existing
engine mount. CNC milling of this mount was done by Star Prototyping of China. I am very
pleased with the quality and precision of their machining. The cost of this mount was about $460
delivered. As best I could estimate, at retail the metal alone to cut my pieces would have cost
about $250. I could have written the G-code to cut the parts easily enough but estimate it would
have taken me around 80 hours of labor to program and coordinate fabrication (staging,
clamping, tool packs, clear planes, verification, etc.). In the end it seemed like a bargain to have
someone else do that work.
Replaced stock power steering rack with Honda Civic manual rack and pinion. It’s hard to turn the
wheel at a dead stop but very manageable while rolling.
Replaced stock flywheel with a Fidanza Aluminum flywheel purchased from Amazon. This
flywheel is 10 lbs lighter than the original.
Adding a brake pressure transducer to the brake lines in order to have a smooth gradient on
brake regen. Still a work in progress.
Netgain Controls WarP-Drive Cable-Drive Throttle Assembly. A very smart looking Hall effect
cable pull throttle unit that I attached to the heavily modified original cruise control actuator
Custom controller heat sink shaped from a section of IGBT aluminum heat sink stock purchased
on eBay. The controller is mounted where the original A/C condenser was located. This should
provide plenty of cooling air to the heat sink fins.
Custom battery boxes built with welded aluminum frames and riveted aluminum skins:
13 cell trunk box
17 cell rear engine compartment box
6 cell front engine compartment box
Added a JLD 5740 programmable voltmeter under the hood that displays pack voltage and monitors charging. The intent of this meter is to provide some level of secondary charge protection. Setup to disconnect charger from pack if the pack voltage climbs more than 1V above nominal charge voltage.
|Special thanks to: Jack Rickard (www.evtv.me) for design inspiration and technical assistance; |
Jeff D. for help with metal fabrication, shaping, and design; and Tom C. for some great aluminum
Components purchased primarily from EVolve Electrics and Manzanita Micro. Both were
outstanding to work with and provided great service and patience to a question asking first timer.