MTC 4001Rear BatsPrestoliteCharge PortSystems CheckWiring diagram
OwnerJames Wolfe
Owner's Other EVs1982 Pontiac J2000
1993 Dodge Caravan (TEVan)
1995 Solectria E-10
LocationGlendale, Arizona US map
Web/EmailWebPage email image
Vehicle1988 Pontiac Fiero
A mid-engined commuter car originaly equipped with a 2.5L, 98 Hp 4-cylinder engine that couldn't pass emissions.
MotorPrestolite MTC 4001 Series Wound DC
Additional forced air cooling supplied by an OEM V6 Fiero coil/alternator cooling fan.
DrivetrainStock 5-speed (Isuzu) with the Heavy Duty clutch from the J2000.
ControllerAuburn Scientific Kodiak PWC600-144
96-144V, 680A Water cooled 15KHz MOSFET. Cooling is provided by circulating the windshield washer fluid.
Batteries20 Saft STM5-180, 6.00 Volt, Nickel-Cadmium, Flooded
Date stamped 11-95 to 2-96. These were salvaged from a San Diego Transit Systems city bus.
System Voltage120 Volts
ChargerRussco SC 120-18 SO
120V-18A, PFC Non-Isolated with built-in GFI (on-board).
Off board chargers are a 25A Bycan that is isolated along with a 12A, 0-144V unit built from 2 - 36V golf cart chargers, bridge rectifier, fans, relay, meters, a timer and a 30A Variac. (Yes, it has wheels).
HeaterI have a ceramic element that is not installed yet, heat is NOT high on the priority list in Phoenix.
DC/DC ConverterIota DLS-30
My first DC-dc was a Todd PC-30b that failed while doing an equalization charge when the voltage went above 160V, the Iota is not connected during charging.
InstrumentationStock Tachometer, with the instrument panel warning lights rewired for "Precharge" and "Run". The rally guages are modified for pack Volts/Battery Amps to provide immediate feedback and I have a Link-10 E-Meter mounted on the center console.
Top Speed70 MPH (112 KPH)
It will go faster but I have no need to drive above the speed limits. I am not childish or paranoind enough to believe I will get 'run over'.
AccelerationQuick enough to not hold up traffic and slow enough to not draw attention. Quicker off the line than stock. I am limited by the 250A circuit breaker in the middle of the pack.
Range60 Miles (96 Kilometers)
The first range test with the NiCd pack yielded 29 miles and ended when I blew the negative pack fuse which 'smoked' the E-meter. The second test went 60.4 miles to about 80% DOD. (no E-Meter to accurately determine SOC) It does 50 miles easily.
Watt Hours/Mile300 Wh/Mile
Worst was 384 for a 20 mile trip that got 178 on the return leg. Best case was 164 for a 31 mile trip while trying for lowest draw, (EV mode). Normal, (ICE type driving), yields about 240 on flat streets with 40-45 Mph speed limits and using routes with 1/4 to max - 1/2 mile between stop lights. Expressway driving, (in the diamond lane), at 65+ Mph and no real hills is about 300. Note that these measurments are with the E-Meter.
EV Miles
Start:125,127 Miles (201,329 Kilometers)
Current:129,587 Miles (208,505 Kilometers)
Total:4,460 Miles (7,176 Kilometers)
 
    As of 9/6/2008
Seating CapacityLimited to 2, (It only has two seats with seatbelts).
Curb Weight3,390 Pounds (1,540 Kilograms)
Up from ICE curb weight of 2490 lbs.
(The Tech-4 weighed 302 lbs without the flywheel, pressure plate and clutch disc.)
Tires205-70R14 Signet inflated to rated pressure +10%.
Conversion TimePulled the ICE in August of 2002 and installed the NiCd's in September of 2005 after it had been de-insured for a year. I would estimate 200, +/- 40, manhours at that point but, it's never done.
Conversion CostSlightly under $6500, which includes purchasing the J2000 for $1800. After driving the J2000 for 2+ years it provided the motor, adapter plate, coupler, vacuum pump, potbox, battery cables and both chargers. I also used its lead acid batteries for the next 3 years.
The doner vehicle cost $500, upgraded Controller was $900, and the 10 year old NiCd batteries were $3000.
Additional FeaturesDelco Vacuum pump for power brakes, (Original equipment on the J2000), Manual steering, Tilt, AM/FM, Sunroof and A/C as soon as I get the compressor drive sorted out and built. The remainder of the A/C components are still in the vehicle. (A/C was one of the criteria in choosing the doner.) I also have HF, VHF & UHF amateur radio using a Yeasu FT857d with an ATAS-100 antenna. This required an additional DC-DC which is a 30A Iota.
The chassis was purchased expressly to build an Electric Fiero. The motor/adapter, vacuum pump, potbox, relays, cables, batteries and guages came from the Pontiac J2000. Both chargers were also part of the J2000 package. I had purchased the J2000 knowing the adapter and motor would bolt into and eventually be used in a Fiero. (The Fiero rear wheel drive train is a Celebrity/J2000 front drive train down to and including the tie rods). This was the least expensive way to gather needed parts.

I added coilovers to the rear to handle the additional weight and the fronts are made from '84-'89 Nissan 300ZX Turbo rears. Ride height is now 1/2" lower than stock in the front and 3/4" lower in the rear.

My Watthours per mile dropped considerably after I had a friend put it on the alignment rack for a four wheels alignment. The springs and additional weight had changed the geometry quite a bit. Only the Right Rear wheel was even close to being aligned and the rears were toed out, just the opposite of what it should be. Now it seems to roll forever!

Charging is accomplished by using both the Bycan and the Russco. (The Russco is not isolated but the Bycan is). This delivers 32A CC to about 152V where the Bycan shuts off. The Russco continues at about 7A CV down to 2-3A and then times out. Not exactly the CCcc that Saft calls for but it works well because the NiCd's don't mind the overcharge.. they just use more water.

In Arizona, EV's are exempt from the Emission fees and also the Vehicle Licensing Tax, which is essentially a 4% tax on the manufacturers base price of the vehicle which is set up on a -10% per year sliding scale that never goes below $35. This saves me the $25 Emissions testing fee along with the $35 VLT yearly.

In order to change the fuel type to electric requires taking the vehicle to the Department of Environmental Quality for an inspection and a sign-off. (Where you take your ICE to get a waiver when it won't pass emissions). It was a painless 5 minute process with the inspector very interested in the conversion. He stated that, "We don't see too many of these."

code by jerry