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"Doing our part to help reduce our dependence on fossil fuels (OIL)."
  D&D Motor Systems is the premier EV motor manufacturer in the U.S. for a small to medium light-weight EV conversion. In addition we offer a complete line of U.S. made speed controllers to go with our high performance EV motors (motors for electric cars). Kick the oil habit now. It's a lot more practical than you think. This isn't a dream of the future. With a little effort, electric vehicles (EVs) are here today! At a cost you can afford! We have the best electric car motors for sale in the industry. Most economical EV motor for electric motor car conversion.
 
 
Electric Vehicle Motors | EV Motor | ES-15A | electric car motor
ES-15A-Type
36-72 Volts
EV Controller | Electric Vehicle Controller | Electric Car Controller |  EV motor controller | controller for electric car motor

450 Amp
72 Volts

Download Spec. Sheet
 
Electric Car Motors | EV Motors | ES-31B | electric motors for cars
ES-31B or ES-63 Type
72-144 Volts
  Want a motor and / or controller? (Fill out as much info. as possible)
 
Popular Vehicles for EV Conversions

The best candidates for EV conversion are typically small, lightweight vehicles
   similar to the ones pictured below. Click to view details.
1991 Geo Metro
1993 Eagle Talon
1986 Honda CRX
Custom Ford Coupe

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(Note: Click on thumb-nail image below for detailed spec's and additional pictures with a larger View)
Mitsubishi Eclipse
Pontiac Fiero 1986
Ford Probe GT 1995
VW Beetle - New 1999
Tryckle 2008
1991 Geo Metro
Gizmo
1986 Honda Civic
1992 Electric Tercel
1993 Kewet EL-JET3
1993 Eagle Talon
Dragster - ALL ELECTRIC
Dragster
Ford Festiva - 1992
Trike - XR3
Trike - XR3 - Hybrid
Model T Ford Electric
Model T Electric Drive Train Assembly
Model T Ford Controller Assembly
custom built high performance motors
utility vehicle motor
electric vehicle motors
electric car conversion
motors ev
custom ev motor
electric dump truck motor
72 volt electric motor
hybrid vehicle motors
hybrid vehicle electric motors
electric motors for hybrid vehicle
hybrid vehicle electric motor system
electric hybrid Jeep - EV Power Systems
hybrid Jeep - EV Power Systems
electric motors for hybrid Jeep - EV Power Systems
electric hybrid Silverado - EV Power Systems
Electric MAG XC | electric utility vehicle motor
Columbia MEGA Cargo Bed | ev motor
ev conversion
electric car conversions
electric conversion for car
electric Honda
dc powered Honda
electric vehicle conversion
electric powered Honda
electric VW conversion
electric VW bug
electric volkswagon beetle
vw beetle electric conversion
electric VW beetle
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EV motor | electric car motor
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EV motor
ev motor | electric car motor
electric motor for car | ev motors
electric vehicle motors | ev motor
Electric Cars
Electric Cars
Electric Cars
Electric Cars
Electric Cars
 
Frequently Asked Questions - FAQs  (click question to view answer)
1. Why build an EV?
2. What basic steps are involved?
3. How much will a typical Conversion Cost?
4. How much will I save on gas?
5. Which vehicles are the most commonly used for conversions?
6. What driving range can I expect per charge?
7. How fast will my converted EV go?
8. How do electric cars work?
9. How do I determine the charge state of the batteries?
10. What can I do, to keep the cost per mile as low as possible?
11. How much do batteries weigh?
12. How should I care for the batteries to ensure long life?
13. How long do batteries last before they must be replaced?
14. Why can’t I just use deep-cycle 12-V batteries to save space and weight?
15. Why don't you use Lithium-ion batteries?
16. What size cabling should I use for the high-current connections?
17. Should I use the wing-nut bolt or should I use terminal-post clamps?
18. Can I use an automatic transmission?
19. Why do I need a transmission at all?
20. What kind of meter(s) should I install so I can monitor as I drive?
21. After the conversion, will the vehicle be heavier?
22. Can I make my own adapters (motor-transmission mount, shaft-clutch)?
23. Can I still have air conditioning?
 
1. Why build an EV?
Today there are limited production electric vehicles (EVs) available, so converting an existing internal combustion engine (ICE) vehicle to an electric vehicle (EV) might be the best choice available to obtain an EV. Building your own electric vehicle (EV) can be a rewarding and challenging experience. Not only will you be a pioneer in the EV movement, but you will also be recycling a car that may be headed for the junk yard. Don’t wait for Detroit. Custom build an EV yourself. A typical EV conversion will achieve a range of 30-60 miles for each charge. Studies have shown that 80% of commuters travel less than 40 miles per day, and 50% of commuters travel 20 miles (or less) per day. An EV conversion can meet those daily driving needs. EVs are a clean, efficient alternative to conventional vehicles – using technology that is readily available today! EVs produce zero emissions, and when you consider the full fuel cycle to generate electricity, are up to 99% cleaner than gasoline and diesel vehicles. EV owners enjoy the financial benefits of significantly lower fuel and maintenance expenses. Finally, EVs help reduce our dependence on oil.
D&D Motor Systems does not provide complete electric vehicle (EV) conversion kits. We only provide the motor and controller. To obtain complete kits or other components go to our Links section and look under EV Conversions for potential suppliers.
2. What basic steps are involved?
A.Define the purpose of the vehicle.
 Ask yourself the following questions:
 Why do you want an EV?
 Where will you drive it?
 Who else will drive it?
 How many miles do you require on a daily basis?
 How often will you drive the vehicle?
 With or Without passangers?
 Will your employer allow you to charge at work?
 How much do you want to spend?
 How much time do you have for the conversions?
   
B.Evaluate the vehicles manufactured.
 When you start to evaluate the different vehicles, you will find there are mainly 2 classes out there:
 1.Sports cars, such as the Honda CRX, Pontiac Fiero, Toyota MR2, Porsche 914, Fiat X-19, Nissan Pulsar, MGB or MG Midget. Sports cars have limited space and minimal payload capacity.
 2.Passenger cars and vans, such as the Ford Escort, VW Rabbit, VW Beetle, Saturn, Honda Civic and Geo Metro. The payload capacity for a Geo Metro is about 600 lbs.
   
 Each of these classes have their own characteristics with respect to aerodynamic drag, curb weight, Gross Vehicle Weight Rating (GVWR), passenger compartment, and available space for batteries.
Table 1 lists typical vehicles under each of these classes and their range using various lead acid battery packs (6V and 12V). Range is a function of battery weight because the battery represents the fuel. Typically it takes 15-20 lbs of lead to achieve 1 mile in range. A Rule of Thumb is that 1/3 of the EVs weight should be batteries; the other 2/3 represents dead weight (i.e. frame, suspension, body, motor, etc). If you could decrease this dead weight to 1/2 leaving 1/2 for fuel, you would have superior performance.
   
 
Table 1
VEHICLEICE CURB WEIGHTVOLTAGE OF EVBATTERY MODELEDCURB WT (LBS)AVG RANGE (MILES)
SPORTS CARS
Pontiac Fiero25301205SHP336044
Honda CRX21751205SHP306047
Toyota MR22695144SCS225343040
Nissan Pulsar2025144SCS225286346
PASSENGER CARS
Ford Escort230096T-145345759
Geo Metro1695120SCS225245138
Honda Civic2260144SCS225306340
Saturn23001205SHP316542
VW Rabbit193096T-105296748
Notes
1. Calculations based on spreadsheet developed by Electric Vehicles of America, Inc.
2. Typically curb weight increases each model year.
3. Average range based on 1 percent grade at 50 mph - representing some traffic.
  
 Other Considerations
  
 Front Wheel Drive(FWD) vs Rear Wheel Drive (RWD)
 A FWD vehicle has the advantage of being more efficient; which improves range. However, front wheel drive vehicles typically have smaller engine compartments, which limit the location of batteries. Also, the front -wheel drive vehicle requires more weight (typically 60 percent) on the front axle. If you locate batteries in the trunk, the tail can wag the dog in rain or snow. This is a problem with many Geo Metros with batteries in the trunk.
In addition, the high voltage, high amperage EV controllers and EV motors can produce greater torque and horsepower than the original engine in the smaller FWD vehicles. This can produce a problem. There are two distinct limitations for FWD vehicle. During launch (initial take-off from a standing start) all cars tend to pitch up (front rotates up relative to back.) This is because the center of mass is above the force being exerted by the tires against the road. In a RWD, this pitch tends to plant the driven tires more firmly against the road, thus enhancing traction. In a FWD the effect is opposite. The force pressing the drive wheels against the road is reduced because of the pitch. If power is applied while the car is in a turn, RWD is much more stable. If the rear wheels spin, the car over-steers. If the front wheels spin, the car under-steers and may easily spin out.
  
 Availability of Spare Parts - Age of Vehicle
 Spare parts should be available. This availability is related to the production of that specific vehicle and which part of the country in which you live. Also the availability of after market parts for suspension upgrades can be important.
   
 Manual Vs. Automatic Transmission
  Most EV conversion vehicles are manual transmissions because they are more efficient than automatic transmissions and provide greater range, require less motor torque, require no transmission cooler, and are easier to convert. The problem with an automatic transmission is that it shifts at about 2000 rpm; the electric car motor is usually designed to operate efficiently between 4000-5000 rpm. Consequently, the automatic transmission is a poor choice which results in decreased range. If you buy a vehicle with an automatic transmission, you can replace it with a manual transmission. The additional cost is $150 and up depending on the transmission and used auto parts dealer. Consider trading the automatic transmission.
  
 Power Steering
 Power steering is not recommended because of the continuous power required of the battery system. Even on many of the trucks that get converted, most people eliminate the power steering. The cost to change from power steering to a manual steering box is under $100 and less than 1 hour of work. The equal weight distribution allowed reasonable manual steering.
  
 Power Brakes
 Power brakes are a definite advantage as you increase the weight of the vehicle approximately 800-1200 lbs with the EV parts. In many cases, this represents an increase of 2025 percent in the curb weight of the vehicle. Your goal should always be to have a safe vehicle. Power brakes unlike power steering are only an intermittent energy demand. A typical system requires a vacuum pump and a vacuum switch.
Curb Weight Curb weight is the weight of the vehicle parked at the curb. No passengers and no payload. If you want to have 1/3 to 1/2 of the finished weight in fuel; then the initial curb weight of the vehicle should be less than 3000 lbs. The Geo Metro is one one the lighter vehicles with a curb weight of 1695 lbs. Consequently, an 800 lb battery pack seems ideal, except that GVWR and weight distribution become a major problem.
GVWR and Distribution This is the most important consideration in any vehicle, because this directly affects the safety of the vehicle. As previously stated, converting an existing vehicle to an EV will add 800 - 1400 lbs in curb weight. Check the Gross Vehicle Weight Rating (GVWR) of the vehicle including the tires presently on the vehicle to see if it is designed for this increase. The GVWR and each axle rating are located on the drivers side door jamb. If the GVWR of the vehicle is exceeded, then the vehicle frame, suspension system, and braking system may be beyond their design value.
Although the Geo Metro can perform with an 800 lb battery pack, the payload capacity of the vehicle is 600 lbs. Payload equals GVWR minus curb weight. With two people in the Geo, the available payload decreases to 300 lbs. Consequently, an 800 lb battery pack can lead to braking and handling (See FWD vs RWD above) as well as a long term fatique problem with the unibody. Therefore, the lightest vehicle is not always the best vehicle.
You must also consider where the EV components will be located. Where will the batteries be located; they are the bulk of the additional weight. Will the charger be carried onboard or offboard? How will this change in weight distribution affect the vehicles handling? In the 1973 VW, the majority of weight was on the rear wheels; this was great for snow.
  
C.Select a Vehicle to Convert
   
D.Look for an EV Kit for the vehicle you choose
 Kits will make the conversion significantly easier - they include all the parts, except batteries. A conversion kit will cost about $3,000 - $6,000 and the batteries, depending on how many you need, can cost from $700 - $4,000 , depending on the type you choose.
   
E.Gather the proper tools for the job
 Make sure you have access to the proper tools and supplies, and a place to do the conversion. You may need to rent equipment like engine hoists and contract out welding work. Contact EV veterans for advice and assistance.Go to our Links page, and look under Electric Vehicle Conversions.
   
F.Familiarize yourself with the EV parts
 The most common batteries for EV conversions are lead-acid batteries, specifically, 12-volt sealed batteries.
   
G.Saftey
 Any project involving automobiles and tools has inherent risks. Be aware of these possible hazards to prevent damage to the vehicle and serious injury to you.
   
H.Remove ICE components
 Remove any ICE (Internal Combustion Engine) components, making room for the EV parts.
  
I.Install EV components
 Install the motor, components, battery box, and batteries. Install the wiring for propulsion (traction pack), auxiliary power system (12-volt system), and traction pack charging system, and displays and controls.
  
J.Safety Testing
 Test the battery charger; check the wiring and fuses, connections. Then take it out for a spin and notice the quiet, smooth ride. Be sure to show it off!
  
3. How much will a typical Conversion Cost?
Not counting the cost of the donor vehicle, you will spend between $4,000 and $9,500. It depends on the type of vehicle you are converting, which determines the size motor, controller and number of batteries. The total cost also depends on how much metal work you can do yourself.
4. How much will I save on gas?
Gas Guzzler - Assumptions 
 Milage:20 miles/gallon
  Cost Per Gallon:$4.00 (US Ave.) / gallon
 Cost Per Mile:$0.20 / mile
   
Clean Electric -Assumptions 
 Electricity Cost:$0.07 / kWHr (Kilowatt Hour)
 Recharge Cost:Aprox. $0.84 / charge (12 Kw-hr / Charge)
 Vehicle Range:Aprox. 50 miles / charge
 Cost Per Mile:1.68 cents / mile
   
Savings -Assumptions 
  Savings Per Mile:($0.20 - $0.0168) = $0.1832 / mile
 Annual Miles Driven:12,000 miles / year
   
 Annual Savings:$2,198.40 Per Year
* Annual Savings Do Not Include the reduction in annual maintenance expenses! So, you could save more than estimated above.
5. Which vehicles are the most commonly used for conversions?
Vehicles most often converted have a 4 cyl. engine and a manual transmission.
Heres a list of some of the most common:
VW - Bug or Beetle, Jeta, Golf, Rabbit, SciroccoVW BugDodge Rampage
Dodge - Colt, Shadow, Rampage, Daytona
Ford - Escort and Ranger
Porche 914Ford EscortPorche 914
Honda - Civic
Datsun Pickup
Plymouth - SundanceHonda CivicGeo Metro
Pontiac - Fiero
Geo - Metro
    
6. What driving range can I expect per charge?
Of course it all depends on the conversion – vehicle type along with the number and type of batteries. However, most people who drive electric street vehicles say they get between 30 and 60 miles per charge, without saying what they mean by charge. I believe it is only reasonable to state the range based on a 50% drop in charge capacity. You can go lower, but repeatedly going down to 40% and less capacity (remaining capacity) point will shorten the life of the batteries. Keep in mind that driving habits impact distance. For more detailed information regarding vehicle range, go to FAQ #2 - Section B, above.
7. How fast will my converted EV go?
Depending upon your vehicle type, set-up and application the average top speed is anywhere between 30 - 70 MPH (miles per hour)
8. How do electric cars work?
Electric cars are something that show up in the news all the time. There are several reasons for the continuing interest in these vehicles:
Electric cars create less pollution than gasoline-powered cars, so they are an environmentally friendly alternative to gasoline-powered vehicles (especially in cities).
Any news story about hybrid cars usually talks about electric cars as well.
Vehicles powered by fuel cells are electric cars, and fuel cells are getting a lot of attention right now in the news.
  
An electric car is a car powered by an electric car motor rather than a gasoline engine.

From the outside, you would probably have no idea that a car is electric. In most cases, electric cars are created by converting a gasoline-powered car, and in that case it is impossible to tell. When you drive an electric car, often the only thing that clues you in to its true nature is the fact that it is nearly silent.

Under the hood, there are a lot of differences between gasoline and electric cars:
The gasoline engine is replaced by an electric motor .
The electric motor gets its power from a controller .
The controller gets its power from an array of rechargeable batteries .
  
Inside an Electric Car
The heart of an electric car is the combination of:
The electric motor
The motor controller
The batteries
  
 
 A simple DC controller connected to the batteries and the DC motor. If the driver floors the accelerator pedal, the controller delivers the full battery voltage to the motor. If the driver takes his/her foot off the accelerator, the controller delivers zero volts to the motor. For any setting in between, the controller chops the battery voltage, thousands of times per second to create an average voltage somewhere between 0 and Full Battery pack voltage.
  
The controller takes power from the batteries and delivers it to the motor. The accelerator pedal hooks to a potentiometer (variable resistor), and this potentiometer provides the signal that tells the controller how much power it is supposed to deliver. The controller can deliver zero power (when the car is stopped), full power (when the driver floors the accelerator pedal), or any power level in between.
  
The controllers job in a DC electric car is easy to understand. Let us assume that the battery pack contains 12 12-volt batteries, wired in series to create 144 volts. The controller takes in 144 volts DC, and delivers it to the motor in a controlled way.

The very simplest DC controller would be a big on/off switch wired to the accelerator pedal. When you push the pedal, it would turn the switch on, and when you take your foot off the pedal, it would turn it off. As the driver, you would have to push and release the accelerator to pulse the motor on and off to maintain a given speed.

Obviously, that sort of on/off approach would work but it would be a pain to drive, so the controller does the pulsing for you. The controller reads the setting of the accelerator pedal from the potentiometers and regulates the power accordingly. Say that you have the accelerator pushed halfway down. The controller reads that setting from the potentiometer and rapidly switches the power to the motor on and off so that it is on half the time and off half the time. If you have the accelerator pedal 25 percent of the way down, the controller pulses the power so it is on 25 percent of the time and off 75 percent of the time.

Most controllers pulse the power more than 15,000 times per second, in order to keep the pulsation outside the range of human hearing. The pulsed current causes the motor housing to vibrate at that frequency, so by pulsing at more than 15,000 cycles per second, the controller and motor are silent to human ears.

Most DC controllers used in electric cars come from the electric forklift industry.
  
Electric Car Motors & Batteries
   
If the motor is a DC motor, then it may run on anything from 96 to 192 volts. Many of the DC motors used in electric cars come from the electric forklift industry.

DC installations tend to be simpler and less expensive. A typical motor will be in the 20,000-watt to 30,000-watt range. A typical controller will be in the 40,000-watt to 60,000-watt range (for example, a 96-volt controller will deliver a maximum of 400 or 600 amps). DC motors have the nice feature that you can overdrive them (up to a factor of 10-to-1) for short periods of time. That is, a 20,000-watt motor will accept 100,000 watts for a short period of time and deliver 5 times its rated horsepower. This is great for short bursts of acceleration. The only limitation is heat build-up in the motor. Too much overdriving and the motor heats up to the point where it self-destructs.

Right now, the weak link in any electric car is the batteries. There are at least six significant problems with current lead-acid battery technology:
They are heavy (a typical lead-acid battery pack weighs 1,000 pounds or more).
They are bulky (the car we are examining here has 50 lead-acid batteries, each measuring roughly 6 inches x 8 inches x 6 inches).
They have a limited capacity (a typical lead-acid battery pack might hold 12 to 15 kilowatt-hours of electricity, giving a car a range of only 50 miles or so).
They are slow to charge (typical recharge times for a lead-acid pack range between four to 10 hours for full charge, depending on the battery technology and the charger).
They have a short life (three to four years, perhaps 200 full charge/discharge cycles).
They are expensive (perhaps $2,000 for the battery pack shown in the sample car).
9. How do I determine the charge state of the batteries?
A simple way to measure state of charge is to measure the voltage of the battery bank a couple hours after you have driven it – and before you start charging, of course. The chart below is an example of one used to determine the percent charge remaining. You can make your own chart for the number of batteries you use. The third column, Individual Bat. Voltage, is simply multiplied by the number of batteries to create the first column. Many say that measuring the specific gravity is the best way to determine charge level, but who wants to mess with battery acid!
 
State of Charge - Unloaded
Battery Bank
Voltage - 96V
(16 Batteries)
% ChargeSingle Battery
Voltage
Specific
Gravity
(80°F)
101.901006.371.277
100.96906.311.258
100.00806.251.238
99.04706.191.217
97.9260 6.121.195
96.80506.051.172
95.68405.981.148
94.56305.911.124
93.28205.831.098
92.00105.751.073
 
10. What can I do, to keep the cost per mile as low as possible?
Use low rolling resistance tires and keep the tire pressure up.
Do not be a lead-foot. Its the same as a gas guzzler - take it easy.
Learn to coast a lot - you are traveling for free when you coast.
Use a high-efficiency charger so as not to waste energy while charging.
Plug into the neighbors house instead of yours when charging. (Just Kidding!)
  
11. How much do batteries weigh?
The 6-V golf cart batteries are around 65 pounds each. The 12-V deep cycle batteries are usually about 75 pounds each.
12. How should I care for the batteries to ensure long life?
Use a quality charger that has three charge phases: constant current, constant voltage with decreasing current and a lower constant voltage for the final phase. The final charge phase is often called the finishing phase or the soak-in phase. The charger should also provide a manual equalization charge mode that you can use at wide intervals to restore balance to your series connected batteries. Equalization removes sulphate build-up on the plates and helps restore performance.
Keep the batteries charged.
Do not routinely discharge the batteries down to 40% or less of remaining capacity .
Check water levels in the batteries at least once per month, especially during hot weather. Only add water after charging, not before.
Never add acid to the batteries.
Inspect the battery terminals to ensure they are tight. A loose terminal connector has contact resistance that will create a large amount of power loss in the form of heat and even melt the lead terminal post down.
13. How long do batteries last before they must be replaced?
It depends on many variables. On average about 3 - 4 years.
14. Why can’t I just use deep-cycle 12-V batteries to save space and weight?
Assuming that your goal is to have the same voltage either way, you will have less capacity and range using the 12-V batteries. However, if the vehicle is small and light, 12-V batteries are the best option because of lack of space and the need for less weight. Many Geo Metro and VW Rabbit conversions use 12-V batteries. Realize that these are not 12-V automobile batteries. They are deep-cycle batteries intended for golf cart and other electric vehicle use. 8-V golf cart batteries are also available as a design option.
15. Why don't you use Lithium-ion batteries?
Lithium-ion (Li-ion) batteries are very expensive and they require an expensive charger and protection electronics for each battery. Some companies offer 12-V Li-ion batteries for vehicle applications at a cost of $2500 each plus another $500 each to cover the special electronics and charger. Compare one of these to two 6-V golf cart batteries at a cost of only $130.
16. What size cabling should I use for the high-current connections?
#2 should be the smallest cable size that you use to interconnect the batteries, high-current fuse, circuit breaker, high-current contactor, current shunt, controller and motor. #4 and #6 are smaller diameter sizes that should not be used – too much power loss and heating. Visit your local welding supply store to obtain a flexible welding cable of size #2, #1 or larger.
17. Should I use the wing-nut bolt or should I use terminal-post clamps?
Terminal-post clamps are best because they offer more contact surface area to handle the high current and will stay tight. If you decide instead to use the wing-nut bolt on each terminal post, make sure you use the correct size cable terminal end, usually a 5/16 in. hole and that you use a spring-type lock washer under the wing nut. If you fail to use the lock washer, the wing nut will become loose, contact resistance will increase rapidly, heat will increase dramatically and the terminal post will melt – not pretty.
 
18. Can I use an automatic transmission?
Most EV conversions are manual transmissions because they are more efficient than automatic transmissions and provide greater range, require less motor torque, require no transmission cooler, and are easier to convert. The problem with an automatic transmission is that it shifts at about 2000 rpm; the electric motor is usually designed to operate efficiently between 4000-5000 rpm. Consequently, the automatic transmission is a poor choice which results in decreased range. If you buy a vehicle with an automatic transmission, you can replace it with a manual transmission. The additional cost is $150 and up depending on the transmission and used auto parts dealer. Consider trading the automatic transmission.
19. Why do I need a transmission at all?
This is a very common question. If a transmission is not used, a gear ratio that allows the motor to start easily under load must be used. The idea behind this is to ensure that the motor is not over burdened when moving the vehicle from a dead stop. With such a starting and fixed gear ratio, the vehicle will reach a top speed that corresponds to the top safe RPM of the motor. For example, I can start off in 2nd gear and accelerate to about 30 mph. If the ratio of my second gear is to be used for a fixed gear ratio, my top speed will be about 30 mph. To get higher speeds, gear shifting is needed. Gear shifting allows for increased speed as the electric motor stays within its rpm design range.
20. What kind of meter(s) should I install so I can monitor as I drive?
Most people install both an ammeter and a voltmeter. The ammeter helps you determine when to shift gears and how to optimize the use of the gas pedal and conserve energy. The voltmeter is of little use at all because it will vary widely as you accelerate and coast. The voltmeter cannot tell you the true state of charge until the vehicle has rested for a couple hours. Unless it is a digital voltmeter, it will not be accurate enough anyway. So, an inexpensive multimeter can be used to measure your bank voltage until you are familiar with the discharge and range capabilities. If you have some extra money, you may be able to find a computing meter that keeps track of discharge and shows you what is left.
ex. Embedded Ammeter replaces the fuel gauge
21. After the conversion, will the vehicle be heavier?
Yes. The good news is that it is usually below the chassis and suspension ratings. The weight should be evenly distributed between the front and rear. For smaller vehicles, the suspension system will be challenged, especially with passengers. Add booster springs or shocks with coil springs.
22. Can I make my own adapters (motor-transmission mount, shaft-clutch)?
A few people have done so. However, you need access to a metal lathe and other precision tools. It is a difficult process that requires a precision outcome. Balance and alignment are critical. My advice is to buy these parts already precision manufactured and ready to bolt on. (See our EV Conversion Links)
ex. Typical Motor Adapter Assembly
23. Can I still have air conditioning?
Some people do try to keep the air conditioning. They use a motor that has a shaft sticking out of both ends. The front shaft interfaces with the flywheel and clutch assembly. The shaft sticking out the back end is used to mechanically connect to the airco compressor. Keep in mind that if you do this, you will have no airco when the motor is stopped, which as it turns out is a lot of the time during stops and coasting. Also, the energy needed for this airco comes from your battery bank, shortening your range.

Still have questions? Visit the Q & A section at Wilderness EV.

 
Electric Vehicle News
View Category: All
2012-01-24 15:09:30
An Electric Hybrid Truck Designed For Utility Fleets
  By: Ucilia Wang
Filed Under: Electric Vehicles

If you can soup up a plug-in hybrid electric vehicle, what features would you want? For some fleet managers, turning plug-in hybrids into a source for powering up construction tools or buildings during a blackout is high on the list.

EV parts | EV conversion | electric cars kits

That’ why Pacific Gas & Electric Co. has been helping VIA Motors to convert new General Motors trucks into plug-in hybrids with the ability to export a large amount of power. The utility, the largest in California, envisions sending a bunch of these trucks into the field for routine maintenance work and to deal with emergencies. The amount of exportable power here will be large enough to run hydraulic lifts to send workers up the powerlines to do repairs or serve as backup power for homes while workers fix faulty circuits or transformers, said Dave Meisel, director of transportation services at PG&E.

Hybrid cars offer fuel savings over time – the price of gasoline has risen and will continue to increase at greater rates than the price of electricity – as well as environmental benefits such as lower emissions, he said. As federal andstates introduce stricter fuel economy and emission standards, businesses must comply by buying vehicles with more fuel-efficient engines or ones that run on cleaner sources of fuels. But alternative-fuel vehicles also tend to cost more partly because they aren’t made in large volumes, and fleet managers very much focus on the payback period of their investments.

Adding the exportable power feature creates additional savings for fleet owners like PG&E, Meisel said. It eliminates the need for buying portable generators that run on fossil fuels, for example. Using the hybrid trucks to reduce the length of a blackout also is an attractive proposition for utilities, which face fines if their customers experience a high number of outages or if they can’t restore power quickly.

“We are looking at broader savings that a lot of people are not looking at,” Meisel said. “When I look at the total operational savings, including fuel savings, the math starts to look really nice.” PG&E has about 9,000 vehicles in its fleet, and roughly 3,100 of them run on alternative fuels, such as natural gas, electricity and biodiesel.

PG&E has been field-testing two VIA trucks since last year and giving the car company feedback about its experience and suggestions for improvements. The utility estimates that the trucks could deliver annual fuel maintenance savings of $7000 per vehicle compared with conventional trucks, said Greg Pruett, senior vice president of corporate affairs at PG&E, during a press event at the Detroit auto show earlier this month when VIA discussed its plans to launch not just hybrid trucks but also hybrid SUVs and vans. VIA plans to convert only GM models, such as the Chevy Silverado, for now.

VIA has developed a powertrain that includes a 24 kilowatt-hour lithium-ion battery pack, which can last up to 40 miles per charge. The gasoline engine is for generating electricity to run the electric motor, which moves the wheels. The company is putting its technology in brand new vehicles only, not used cars. When VIA Motors showed up at the Detroit auto show, its executives rattled off a list of things that people can do with vehicles that double as power generators, such as catering to outdoor parties and running outdoor concerts.

“Think of a 3-day camping trip where you have unlimited power with the car you drive into the woods with,” said Bob Lutz, a member of VIA’s board of directors and the former vice chairman of GM, during a press conference at the auto show.

The two VIA trucks PG&E has been trying out cost about $400,000 total, Meisel said. The trucks are the early version of what VIA plans to produce commercially later this year, Meisel said. The price for the trucks at “low volumes” should be in the $70,000 range, and it should continue to drop as production increases, he added.

VIA isn’t the only company PG&E is turning to for converted hybrids with exportable power. The utility also is considering vehicles from Electric VehicleInternational, which turns beefier pickup trucks to plug-in hybrids. VIA’s truck delivers 15 kilowatts of exportable power and is working on boosting that to 50 kilowatts while Electric Vehicle International is working on trucks with 100 kilowatts of exportable power. Figuring out a good way to cool the equipment that generates and routes the power becomes a greater hurdle as the size of exportable power increases.

PG&E and other fleet owners are turning to companies that can do after-market conversion for now partly because major automakers have yet to introduce the plug-in hybrid version of the trucks that the fleet owners want to buy. But that day will come if consumers continue to show interest in electric cars (and the prices for them drop). When that happens, companies such as VIA Motors may find it difficult to compete, said Kevin See, an analyst with Lux Research.

“There may be a short-lived window for them to make their mark,” See said. “I wouldn’t expect their businesses to be long-term because of the competition that will enter the market.”


2012-01-24 15:00:49
Electric vehicle owners can get a ‘charge’ in Media now
  By: Susan L. Serbin
Filed Under: Electric Vehicles

Media Borough has created another reason to make “Everybody’s Hometown” a destination. This time an initiative will make downtown the hometown for owners of electric vehicles (EV).

EV parts | EV conversion | electric cars kits

As only the third known location in Delaware County, Media has inaugurated a charging station in the municipal parking lot next to the Media Fire Department, across from Media-Upper Providence Library and one block from all that State Street has to offer.

The borough is participating in a pilot project for EV charging powered by 100 percent Pennsylvania wind energy. Borough officials and Community Energy, Inc. had the ribbon cutting recently, with attendance by representatives of the energy firm, Mayor Bob McMahon, Councilman Eric Stein, Environmental Advisory Council Chair Walt Cressler and several other borough staff member.

While the technology includes several cutting-edge elements, charging station operation is fairly simple: pull into the dedicated parking space (lot is between Jasper and Front streets just east of Jackson Street); plug the electric vehicle (EV) into the charger; dine, shop or attend to other borough business. In the span of an hour or two, EVs can be charged enough for at least several dozen miles.

“We are pleased to be partnering with Media Borough and the Media Fire Company as this becomes one of the first charging stations in the county,” said Jay Carlis, Vice President of Retail Marketing for Community Energy, Inc. based in Radnor. “This pilot project, funded by the Pennsylvania Department of Environmental Protection, comes early in the electric vehicle transition. At the government level, Media has been a leader in environmental sustainability. This is a great location for residents and visitors.”

Carlis said there are charging stations in Radnor and Wayne and only a handful in the state, placing the borough in the forefront of the technology. To kick off the enterprise, he drove a Chevrolet Volt and hooked it up to demonstrate the virtual plug, charge and go technique.

Representatives from Thomas Chevrolet brought a second Volt. Amy Ercolani of Thomas said the dealership has sold several Volts, has one in stock, and expects the manufacturer to supply a small but steady stream of the model, which has a gasoline back-up capability. EVs are available from other automotive manufacturers as well.

Running at a 240-volt service, the public station works twice as fast as a charge from, for example, a home outlet which is generally half the volts. An hour charge is expected to cost $3.50 with Community Energy paying a fee to the borough for the actual electric used. The mileage value of a charge varies depending on vehicle and road conditions, not unlike gas mileage. Not surprisingly, there are “apps” which can monitor the charge from mobile devices.

In the borough’s view, the station sends multiple signals about the alternative energy commitment which already includes a solar energy grid and wind-generated electricity purchase.

“I’m a strong supporter of renewable energy. I have solar energy at my home, so I’m not just talking theoretically,” said Stein, liaison to the Environmental Advisory Council. “It’s good for the economy, and good for the environment.” Continued...

 


2009-03-13 07:25:30
General Motors and Iberdola to study EV charging infrastructure in Spain, UK
  By: Sam Abuelsamid
Filed Under: Electric Vehicles

General Motors will be collaborating with Spanish energy company Iberdola on a feasibility study to determine the infrastructure needs to support plug-in vehicles in Europe. Similar studies are underway already between automakers and utility companies in the United States and elsewhere. The two companies have a relationship through other projects being run by EPRI. Under examination will be the needs for private, residential, and commercial customers as well as for publicly-accessible vehicle plugs. Among the issues that need to be resolved are how rates will be determined for vehicle charging and billing mechanisms. The study will be focused in Spain and the UK.


2008-09-30 07:53:54
Chrysler Unveils Dodge EV
  By: Ray Wert - Jalopnik.com
Filed Under: Electric Vehicles

A Tesla-Like All-Electric Sports Car

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Today on CNBC, Chrysler CEO Bob Nardelli revealed a Tesla -like all-electric performance sports car called the Dodge ev along with three other vehicles operating either partially or entirely on an electric powertrain. The four vehicles are Chrysler's ENVI electric car program, and include an extended -electric Chrysler minivan, a new "gated community" electric called "the peapod" and a Jeep Wrangler four-door. The ev, the first of the four unveiled, not only operates entirely on plug-in power like the Tesla Roadster and appears to have similar performance numbers, also has some striking visual similarities with the Tesla. And why shouldn't it? While the Tesla's built on the Lotus Elise, the Dodge ev appears to be based on the Lotus Europa.


2008-08-14 12:56:49
Utilities: Grid can handle influx of electric cars
  By: AP
Filed Under: Electric Vehicles

Which draws more juice from the electric grid, a big-screen plasma television or recharging a plug-in hybrid car?

The answer is the car. But the electricity draw by plasma televisions is easing the minds of utility company executives across the nation as they plan for what is likely to be a conversion of much of the country's vehicle fleet from gasoline to electricity in the coming years.

Rechargeable cars, industry officials say, consume about four times the electricity as plasma TVs.

But the industry already has dealt with increased electric demand from the millions of plasma TVs sold in recent years. Officials say that experience will help them deal with the vehicle fleet changeover.

So as long as the changeover from internal combustion engines to electric vehicles is somewhat gradual, they should be able to handle it in the same way, Mark Duvall, program manager for electric transportation, power delivery and distribution for the Electric Power Research Institute, said Tuesday.

"We've already added to the grid the equivalent of several years' production of plug-in hybrids," Duvall said at a conference on electric vehicles in San Jose. "The utilities, they stuck with it. They said, 'All right, that's what's happening. This is where the loads are going, and we're going to do this."'

Automakers, such as General Motors Corp. and Toyota Motor Corp. , are planning to bring rechargeable vehicles to the market as early as 2010. But speakers at the Plug-In 2008 conference say it will take much longer for them to arrive in mass numbers, due in part to a current lack of large-battery manufacturing capacity.

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2008-08-14 12:49:37
A New (Good) Look for Electric Cars
  By: JACK LOSH / LONDON
Filed Under: Electric Vehicles

Electric cars have been around for almost 170 years, but it's not just the limitations of battery power that have thwarted their more widespread use. Since Scottish businessman Robert Anderson pioneered the first electric carriage in the 1830s, most electric vehicles have lacked one of the key markers of auto success: good looks. Just take a look at La Jamais Contente, designed by Belgian Camille Jénatzy in 1899, or Billard and Zarpe's space-age oddity, the Elektra King (1961). Even today's models — the REVA, or Zap!'s Xebra — are proof that the best adjective to describe most electric cars remains quirky.

Now two new models show that green can be given a devastatingly cool makeover. Britain's Lightning GT and the U.S.-built Tesla Roadster both reach 60 m.p.h. in 4 seconds or less, their makers claim, with top speeds approaching 130 m.p.h. The Lightning GT — unveiled at London's International Motor Show last week and set to be available from the end of 2009 — sports an impressive, sleek and sexy design, drawing on Aston Martin's classic British look. Tesla, which launched its hot, little open-top two-seater a couple of years ago, has already sold out of the 2008 model and is eagerly taking reservations for 2009. Battery power has rarely, if ever, looked this good.

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2008-08-14 12:14:39
Converting gas-powered cars to electric
  By: Curt Merrill - CNN
Filed Under: Electric Vehicles

Larry Horsley loves that he doesn't buy much gas, even though he drives his '95 Chevy S-10 back and forth to work each day.

Horsley, a self-described do-it-yourselfer, simply plugs his truck into an electric wall outlet in his Douglasville, Georgia, garage and charges it overnight, instead of buying gasoline refined from mostly imported oil.

"If I can keep a dollar from going overseas, I'll spend two dollars," he said. The whole conversion, including the truck, cost him about $12,000, which parts dealers say is about standard.

Another Atlanta-area tinkerer, David Kennington, converted his Honda Civic del Sol from gasoline to electric for a different reason: "I'm a raging greenie," he said.

Both Horsley and Kennington are fed up. They're among a growing number of Americans who are refusing to wait for big-car manufacturers to deliver mainstream electric vehicles, called EVs. Not only have they rebelled against the status quo by ripping out their gas-guzzling engines and replacing them with zero-emission electric motors, they say just about anyone can do it.

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