ELEC KAR rearAt EarthdayAt Parade
OwnerMark E. Hanson
Owner's Other EV2009 Sun Go
LocationFincastle, Virginia United States map
Web/EmailWebPage email image
Vehicle1974 Volkswagen Karmann Ghia
36ea CALB-130 batts for a 120VDC system (incase the house power goes out :-) with a 9" Warfield Netgain motor (same length as the 8" ADC). Charger is a modified 36V GC charger with a MC68HC908QY4 freescale uP programmed to cut back the charge current to 1A when any one of the 36 3.6V regulators starts regulating or the bulk charge hits 126V. Initially I built my own controller but now have a Curtis 1231C installed. All new brakes, bearings and helper springs, restoration, about $10k in car and $15k in conversion. Took me about a year with all the pesky battery balancers and associated monitoring circuitry to detect 4.0V and any wire/fuse popping off to stop the charger, then test each cell for proper failsafe operation.
MotorNetgain short 9 Series Wound DC
This is a 9" motor, same length as an ADC 8"
Drivetrainstandard VW bug tranny replaced after AAMCO trashed the first one (handed back in a box of parts, couldn't get humpty dumpty back together again). The adapter had to be modified a couple times due to clearance from lightenned flywheel to clutch. A 9" Netgain Warfield motor was used.
ControllerCurtis 1231C
Inside enclosure with contactors and muffin fan on heat sink between the back seat and firewall next to custom charger.
Batteries36 CALB/Skyenergy CALB 130ah, 3.30 Volt, Lithium Iron Phosphate
lithiumstorage.com did a great job banding the cells together in groups of 6 for nice placement of 6 batteries totalling 360 lbs (instead of 1k lbs for a lead sled)
System Voltage120 Volts
ChargerLester modified 36V golf cart charger for 130V charging
The 36V charger was tweaked into a push-pull fashion with the upper and lower diode to the end pack and the other transformer winding to the battery center tap with a few windings on the secondary tapped down to get 129.6V final charge for 3.6V x 36 cells.
Heater2ea blow dryers mounted under dash and one for defroster elephant snotted into ductwork.
DC/DC ConverterIota 120VDC
InstrumentationThe all important battery scanner was built in stereo to monitor all the 36 cells simoultaniously. Link-Pro battery AH meter is used to see AH in and out during run/charge.
Top Speed65 MPH (104 KPH)
Gets there eventually about 15 seconds I guess, not a race car but keeps up with traffic and gets me to-from work which I need to do to pay for the car :-)
Accelerationabout 15 seconds 0-65 I think
Range40 Miles (64 Kilometers)
At freeway speeds, no cheating :-)
Watt Hours/Mile240 Wh/Mile
At wall outlet actually about 300whr on this 2200 lb car. My E-Porsche was 3k lbs with ni-cads and 330whr so lighter saves some juice and handles *much* better.
EV Miles
Start:72 Miles (115 Kilometers)
Current:72 Miles (115 Kilometers)
Total:0 Miles (0 Kilometers)
    As of 6/27/2012
Seating Capacity4 sorta (back seat is for kids only)
Curb Weight2,200 Pounds (999 Kilograms)
Start weight was about 2000 lbs for a 1974 Ghia, gained about 200lbs of battery weight.
Tiresregular bimbo bug tires 5.6x15
Conversion Time600 hours, about 250 hours just on the balancers.
Conversion Cost$25k including vehicle (coulda had a Leaf)

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