First Day at Home24 kWh of Chevy Volt PacksLED HeadlightsTrip DistancesStorage UnderhoodBattery InsulationFord Focus SpringsTiny CarGages Mounted more cleanly
OwnerKraig Schultz
Owner's Other EVs1975 Honda CB-125S
Human-Electric Hybrid
Sail Trike
2008 Custom BugE
Tilting Delta Trike
Schultz Engineering Delta-11
Motorized Mtn Bike 2 - Schwinn
Motorized Mtn Bike 1 - Hummer
1987 Kann Linear LWB
LocationGrand Haven, Michigan US map
Vehicle1990 Ford Festiva L
Original owner purchased car brand new in 1990
and converted it immediately to an EV using
Lead Acid.

With over a thousand lbs of lead acid and no
vacuum assist on brakes car was slow and
didn't stop well.

Driven 2,700 miles then, stored inside for 20+

"Re-born" in 2015 by replacing Lead Acid
Batteries with Chevy Volt Batteries.
MotorGeneral Electric SB11346B51 Series Wound DC
23 HP, Air Craft Starter Motor?
99.4 V, 201A, 3285 RPM

FS 456 motor brushes, 1.240" wide x .5" thick x
1.5"-2" long with 3" leads
Drivetrain5 Speed Manual Transmission. Front Wheel
ControllerCurtis 1221B-7401
Ser. Number 58632
72-120Volt, 400Amp

400A/2Minutes, 250A/5Minutes, 150A/1Hour
BatteriesChevy Volt Gen. 1 Lithium Maganese Oxide -, 112.00 Volt, Lithium-Ion
Pack is three to five, modules of 28 cells
each. Each module fused w/175A fuse.

Each module is about 4.5 kWh maximum capacity
and weighs 100 lbs. The modules swap in and
out of car to motorcycle based on weather.

Each module has 45Ah but only use 66% of that
in real world driving to protect battery cycle
life. Run pack from 112 Volts to 100 Volts
(4.0V-3.57V per cell)

for details of how volt batteries was chopped
up for use in motorcycles AND in electric car
(modular, quick swap).
System Voltage112 Volts
Charger Ecotality LSV-100
On-Board = Custom chargers made from switching
power supplies in Series and Parallel. 3.8kW

At Home = Ecotality LSV-100, GEM Car DC Fast
Charger 8kW
HeaterNovember 28, 2015 Installed 1300 Watt PTC
heater from EVTV - not enough to melt snow on
windows, so parked when it snows.

Pre-Heat with 110VAC 1200 watt heater on
timer. If car interior is pre-heated before a
ride stays warm to destination. E.G. Start
at 90 degrees F, 10 miles later it's still
over 70 degrees F even when it's 30-40 degrees
outdoors. Also, helps with keeping window
clear of interior fogging.

Batteries have heating pads to keep them over
40 degrees.
DC/DC Converter Thunderstruck TSM144DC-DC
96-144 volt input,
12-13.8V Output, 50A max output at 12V

Low voltage cut-off is 80V.
Instrumentation-Cycle Analyst
-Kill-A-Watt EZ meters from the wall
-Hoyt Trumeter Programmable Volt Meter (works
like a gas gage - and changes color based on
battery state of charge)
-Temperature gages monitor battery temps.
-Factory Speedometer for velocity and
-Android phone velcro'ed to dash for
navigation and radio
-Custom Arduino blue tooth/cell phone text
app. that texts battery voltage during
charging to my cell phone so I can keep an eye
on charging progress remotely.
Top Speed69 MPH (111 KPH)
69 mph on the flat with grill block and front
belly pan
Acceleration0-45 in 14 seconds
0-55 in 20 seconds

Keeps up with normal commuting traffic.

I take off in 2nd gear to 20-25mph, then shift
to 4th 20-69 mph.
Range50 Miles (80 Kilometers)
30-50 miles depending on how many battery
modules are in car. 10 miles range/module
Watt Hours/Mile305 Wh/Mile
Averaging 305 Wh/Mile from wall driving normal
traffic/commuter speeds (May 2017)
EV Miles
Start:2,750 Miles (4,424 Kilometers)
Current:14,312 Miles (23,028 Kilometers)
Total:11,562 Miles (18,603 Kilometers)
Seating Capacity2 in front seats. Rear seat was taken out
for batteries.
Curb Weight2,410 Pounds (1,095 Kilograms)
1,810 lbs Car includes Electric Motor
+ Traction Batteries (300-500 lbs)
+ Charging equipment (100 lbs)
=2,410 lbs total

Has about 40 Hp peak in operation so that is
54 lbs/Hp.

With a Tesla Drive Train (416 Hp, 443Ft-lbs)
it would approach 5.16 lbs/Hp 4.8 lbs/ft-lbs).
Compare this to the 2015 Supercharged ZO6
Corvette that has 5.26 lbs/Hp, 5.42 lbs/ft-
lbs.. Someday, this little car may be a
Corvette Slayer!
TiresYokohama 372 All Season Steel Belted Radial
Size: 145-SR-12
Conversion Cost$2,000 purchased as is with Lead Acid
batteries Running vehicle.
(August 2014)

+$2,400 for 16kWh 2012 Chevy Volt battery pack
with 14k miles (April 2015)

+$700 for another 8kWh Chunk of Volt Batteries
(Oct. 2016)

+$400 for instrumentation (Cycle Analyst, Hoyt
Voltage meter, temperature gages)

+$200 LED lighting -

+$300 for battery heating pads from EVTV

+$300 for 1300 Watt passenger heater from EVTV

+$200 for Electric Vacuum Pump for power
brakes 12/12/2015

+$200 Arduino/BlueTooth/Cell Phone Text App
that texts voltage status during charging

+$350 10kW DC fast Charger bought on Ebay
Sept. 2017

+$165 600W DC-DC Converter Sept. 2017

Shopping for a used Leaf for our next car.
Additional FeaturesElectric Vacuum Pump for Brakes - Runs on 12 Volt system. Made car
stop - don't know how I drove it before. Very nice. Added December
12, 2015.

Use clutch pedal switch to pre-charge controller capacitors before
switching on the main contactor.

code by jerry