Tilt BedChevrolectric bowtieWarp 9 transplant at GreenShedTailpipe Humor
OwnerPhilip Sutton
LocationLithia, Florida United States map
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Vehicle2003 Chevrolet S10
Regular S10 pickup truck, RWD, standard cab,
long bed.
MotorNetgain Warp 9 Series Wound DC
double shaft
Drivetrain5 speed manual w clutch & 3.73 rear end
ControllerManzanita Micro Zilla 1000 amp
Batteries70 CALB/Skyenergy CA180FI, 3.20 Volt, Lithium Iron Phosphate
all cells "Top Balanced" to .001 volt using
PowerLab 8 battery tender = I do not use a
BMS.
I check all cells every 3-6 months, always
within .1 volt.
40.3 kWh pack - useable (80%) 32.3 kWh
System Voltage224 Volts
ChargerElcon PFC5000
220/110 VAC multi voltage charger
Great CC/CV charger! Doesn't start charge cycle until it senses input power (= no sparking when plugging it in).
Slowly builds up to max 20A charging amps, slowly ramps down to 0A after reaching cutoff voltage (CV mode) (= no sparking when disconnecting plug).
Full charge would take 7 hours, my normal charge time is 2-4 hours each day.
Heater2x ceramic 1500 watt elements (space heater)
- each runs directly off main 224vdc battery via 12v relay.
Gives 100 F heat, perfect to warm cab or defrost windshield.
DC/DC ConverterIota 45 amp
wired constant on, nice HD charger;
Wired w #6 & 50A fuse, lighter wiring & fuse will 'smoke test.'
InstrumentationJLD-404AH meter - track AH used each trip;
also will display amps, volts, and hour meter. I reset to 0 after each charge to see 'fuel' usage (my max is 144ah).
This helps me treat my batteries nice.
I never use more than 75% available battery, I want my batteries to last a long time (20 years would be nice).
Top Speed70 MPH (112 KPH)
70 mph fastest I have driven vehicle, still has plenty of pedal, converters say it should go 120+.
AccelerationVery good, plenty peppy & Faster Than Most!
Have not done any timed accel tests.
Performance is very satisfactory, my main focus is on drive-ability & enjoying the ride.
Range96 Miles (154 Kilometers)
Range varies w driving conditions & driving style; cold temps also seem to have mild negative affect on 'mileage'; Range = 85 miles in average driving & 96 miles w conservative driving.
[32.3kWh / 380 Wh/mi = 85 miles range avg]
[32.3kWh / 336 Wh/mi = 96 mi conservg]
Watt Hours/Mile380 Wh/Mile
average driving = 380 Wh/mile;
conservg driving = 336 Wh/mile.
EV Miles
Start:95,582 Miles (153,791 Kilometers)
Current:112,205 Miles (180,537 Kilometers)
Total:16,623 Miles (26,746 Kilometers)
Seating Capacity2 - bucket seats in standard cab
Curb Weight3,400 Pounds (1,545 Kilograms)
includes 900 lbs LiFePO4 cells;
truck has 800 lbs payload capacity
TiresOEM = UniRoyal Tiger Paw II P205/75R15 97S
Conversion TimeInitial conversion 1-20 Sep 2016,
'assisted conversion' by Green Shed & owner.
Total time = 20 days.
Plenty of 'tinker time' since w upgrades &
improvements.
Conversion Cost$5k for 2.2L 5 speed truck in running
condition w PS, PB, AC all working.
$10k electric motor, controller and other
parts.
$20k batteries (70 ea 180ah CALB LiFePO4)
Monthly electric charging $35 avg.
Driving past gas stations - PRICELESS!!
Additional FeaturesElec AC - MasterFlux Sierra 206 (1500 watts)
- works great, nice & cool (esp @ stop lights in S Fla)
- cooling aided w 3M Crystalline window film, windshield sun
shade, dash mat (made BIG difference - that dash gets HOT!)
Elec PS - EPAS 12v motor from Saturn Ion w assist set HI
- also changed steering to manual box, EZ & precise
Elec PB - Hella UP28 12v vacuum pump at 22 Hg
- vac reservoir maintains supply for brakes & AC actuators
EVSE = 30 amp RV outlet in carport (23A max charging)
Charging connector under gas cap w NEMA L1430 flanged inlet
12V battery charging system LED light in dash (Grn/Y/R)
Liquid cooling kit for controller (EV West)
Tilt bed - hinged to access batteries (Steve @ Green Shed)
Tilt bed - air springs help lift bed (2x 250lb @ Grainger)
Brakes - stock system w front Hawk HPS pads & rear Porterfield Kevlar shoes = 50% more stopping power
Front suspension - 1-1/4" Hellwig sway bar & HD springs
Rear suspension - Add-A-Leaf & SuperSprings give level ride w 900 lbs batteries = overall ride ht 1" higher than stock
Shocks - Bilstein 46mm HD off-road
Clutch - Hayes Severe Duty off-road clutch (w EZ pedal feel)
Hood vents - remove hot AC condenser air from under hood
"100% Electric" emblems sides & rear
Fake tailpipe humor in rear "What Is That ????"
OK, this is fun to drive! Tinker Toy is my daily driver, drives nice & smooth. My original intent was to have an electric conversion pickup truck to use as a truck, looked stock, would drive nice, handle well, be comfortable to use, have a decent range (approx 100 miles) and keep up with traffic easily. I worked with Steve and Audrey at Green Shed to select donor and parts, and then we made it!
I kept my creature comforts; AC, heat, Power Steering, Power
Brakes. Original system was serpentine belt w OEM PS pump & AC compressor. I like separate elec systems better. AC works great, PS is 1-finger EZ turn, heat nice for 4 days of winter/year here, PB stop truck real good. Truck goes & stops well, no body roll in corners, handling is precise, ride is firm and comfy.
Sometimes I pull into a gas station to fill up gas cans for mower & generator, get some funny looks & questions :). It's Fun To Do!!
So I have what I was looking for, still have things to make nicer, easier, better (under hood wiring comes to mind). I get to drive my electric hot rod Tinker Toy on the road, put groceries, chainsaws & wood in it, and play with & 'evolve' it. Fun to drive! Works great!
If you would like specifics on something I've done or found a
better way to do things, drop me an email, I'd appreciate it.

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