tag:blogger.com,1999:blog-39363116511174571382024-02-21T02:20:55.086-08:00Electric PorscheDocumenting the process of converting a gasoline automobile to run on electricity.Joeyhttp://www.blogger.com/profile/01042435434585986098noreply@blogger.comBlogger65125tag:blogger.com,1999:blog-3936311651117457138.post-53764910935072642142018-01-17T16:03:00.002-08:002018-01-17T16:03:52.460-08:00New Project, New BlogMy friend Paul asked if I would help him with a new electric vehicle conversion project. The blog with all the details and latest progress is located <a href="https://elementalenergyev.blogspot.com/" target="_blank">here</a>.<br />
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The project is actually two vehicles.The first is a <a href="https://en.wikipedia.org/wiki/Volkswagen_Type_2_(T3)" target="_blank">1985 Volkswagen Transporter</a> Double Cab or Doka.<br />
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The second vehicle is a <a href="https://en.wikipedia.org/wiki/Austin-Healey_Sprite" target="_blank">1965 Austin-Healey Sprite</a>. <br />
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Joeyhttp://www.blogger.com/profile/01042435434585986098noreply@blogger.com0tag:blogger.com,1999:blog-3936311651117457138.post-81904558445252029452014-11-15T01:10:00.000-08:002014-11-15T09:14:55.019-08:00Fiberglass<span style="font-size: small;">Removing the engine leaves behind some vestigial elements. The first is cosmetic, but the opening under the left side of the bumper for the exhaust pipe really bothered me.</span> <br />
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I made a foam core fiberglass plug to fill the void. I reinforced the mounting location with a strip of plywood inset with t-nuts. The epoxy resin used to lay-up the fiberglass soaks into plywood and protects it from water and rot. <br />
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After primer, lots of sanding, factory match paint and clear coat,
the new plug is mounted on the frame I built for mounting the radiator. <br />
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The rear deck grill is vented for dumping engine waste heat and cooling the air conditioner condenser. The air conditioner was already removed before I got the car, and water and electricity don’t mix, so I need to seal that vent up. My first attempt to make a fiberglass tray failed miserably. I tried to make separate fiberglass parts using the deck lid opening and grill as molds. I lined the car parts with plastic wrap to serve as a mold release and keep the car clean. I used expanding foam to fill the voids. The part ended up being too bulky after gluing everything together. The epoxy didn’t sand down very well either. I keep the failed part on hand to remind myself to slow down, take a break, and start over if I find that the quality of my work is not good enough. <br />
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A second attempt worked much better. I glued up and carved a block made
of pink foam-board house insulation. <br />
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The trick to a smooth finished part
was to coat the foam with a mix of epoxy and a filler called
micro-spheres. The filler with spheres is easy to sand, and the mixture
doesn’t weigh as much as straight epoxy. Once the core is smooth and
sanded to the correct shape, fiberglass cloth and epoxy layup gives a
light and strong part. <br />
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Finished with primer and flat black paint, the
tray blends right in with the stock grill. <br />
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The last detail to
weatherize the motor compartment is an edge grip weather strip that
forms a seal with the deck lid. We get a lot of rain in the Pacific
Northwest. I’ve been driving the car daily for a while and everything is
staying dry in the back.<br />
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<br />Joeyhttp://www.blogger.com/profile/01042435434585986098noreply@blogger.com4tag:blogger.com,1999:blog-3936311651117457138.post-39790167320567373712014-06-29T21:50:00.002-07:002014-06-29T21:50:16.588-07:00Oregon Wine Country<!--[if gte mso 9]><xml>
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My family was in town. It was a chance to show off my electric car. What a proud moment it was for me to show my grandfather the project.<span style="mso-spacerun: yes;"> </span></div>
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I always assumed I inherited my mechanical aptitude from my grandfather – he’s a carpenter and gave me some of my first tools. A few weeks ago I learned that an affinity for modifying cars is also shared. He told me about his 1931 Chevy Coupe that looked a little like this one:<br />
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He installed an Edelbrock four barrel carburetor and changed the gearing in the rear end to increase the top speed to 88 MPH. That was fast enough - I think the statute of limitations is up - to outrun the cops. It is funny that I never heard that story as a kid. All the good family stories are like that. <br /><br />Even though I never opened it up all the way, cornering on wet pavement was sharp enough to give my grandpa the impression that my electric car is not slow. Going down the road with your butt 6 inches above the pavement helps with the perception of speed. <!--[if gte mso 9]><xml>
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<![endif]--> The total trip was about 70 miles and the car had plenty of range to spare. <br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhRGNfL7CvyXkBslV81ZI4DPxUrGThQ_cvap4Hpu-AcugITbiHLpyOQkqwUjlyxu_VQff3t40JV7lzRHnyhmS-PCQm46GhyphenhyphenIgKzooPZ1QhiJ_pvznzFTvGaNMyoxvLAQLM0KnH10ZAtNso/s1600/Wine+Country.JPG"><img border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhRGNfL7CvyXkBslV81ZI4DPxUrGThQ_cvap4Hpu-AcugITbiHLpyOQkqwUjlyxu_VQff3t40JV7lzRHnyhmS-PCQm46GhyphenhyphenIgKzooPZ1QhiJ_pvznzFTvGaNMyoxvLAQLM0KnH10ZAtNso/s1600/Wine+Country.JPG" width="640" /></a><br />In the hills near Dayton, Oregon at the vineyard of Domaine Drouhin.<br />
<span style="font-family: "Calibri","sans-serif"; font-size: 11.0pt; line-height: 115%; mso-ansi-language: EN-US; mso-ascii-theme-font: minor-latin; mso-bidi-font-family: "Times New Roman"; mso-bidi-language: AR-SA; mso-bidi-theme-font: minor-bidi; mso-fareast-font-family: Calibri; mso-fareast-language: EN-US; mso-fareast-theme-font: minor-latin; mso-hansi-theme-font: minor-latin;"><span style="mso-spacerun: yes;"></span></span><br />One of the wineries, <a href="http://www.sokolblosser.com/cheers/blog/2014/4/682/oregon-wine-country-celebrates-earth-day.html" target="_blank">Sokol Blosser</a>, had a new tasting room and was set up with several large photovoltaic arrays and an electric car charging station.<span style="font-family: "Calibri","sans-serif"; font-size: 11.0pt; line-height: 115%; mso-ansi-language: EN-US; mso-ascii-theme-font: minor-latin; mso-bidi-font-family: "Times New Roman"; mso-bidi-language: AR-SA; mso-bidi-theme-font: minor-bidi; mso-fareast-font-family: Calibri; mso-fareast-language: EN-US; mso-fareast-theme-font: minor-latin; mso-hansi-theme-font: minor-latin;"><span style="mso-spacerun: yes;"> </span></span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgZeeKANbZM8W7-y02qKdUvopNjRCn2MyHBoAK-fXjggdv8ERXni_4DdtPRhvkNstguSueLDdgMtpoaQR1l4PQQoh7VLh8JTn45dU0uc2DCTaRJk2DNGT7LS8n8uQ-_-ggCtTCeURGnYfY/s1600/Sokol+Blosser.JPG"><img border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgZeeKANbZM8W7-y02qKdUvopNjRCn2MyHBoAK-fXjggdv8ERXni_4DdtPRhvkNstguSueLDdgMtpoaQR1l4PQQoh7VLh8JTn45dU0uc2DCTaRJk2DNGT7LS8n8uQ-_-ggCtTCeURGnYfY/s1600/Sokol+Blosser.JPG" width="640" /></a><br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgqbLCx7MfoVSZdYv2TrkANdGEzTWYw2M7Mwuk1ybzbtSJdamuv4yGb-_e0duP9R24ejbOyr3-pcVVFiLKaPpva6J-JO_gENgn9VKHxXzmlF6lLrcQ-NZR62GhEeqKsy5GeOtlCrdC3Bco/s1600/Sokol+Blosser+Charge+Station.jpg"><img border="0" height="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgqbLCx7MfoVSZdYv2TrkANdGEzTWYw2M7Mwuk1ybzbtSJdamuv4yGb-_e0duP9R24ejbOyr3-pcVVFiLKaPpva6J-JO_gENgn9VKHxXzmlF6lLrcQ-NZR62GhEeqKsy5GeOtlCrdC3Bco/s1600/Sokol+Blosser+Charge+Station.jpg" width="480" /></a><br /><!--[if gte mso 9]><xml>
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<![endif]-->I didn't plug into the charger because I haven’t bothered to install a J1772 outlet on the car. I have plenty of range for my current driving needs and do all of my charging at home. If my driving habits change and I need to charge away from home, there are kits I can install to use these charging stations that are popping up all over.<br /> <br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhWaY0KTX8S0t8NEzllL0cMqIZrm_IsAbzxyjalKVKoV1rZ7qqgNRNITjlQr3vZmtnysav9xz3qo09_g1_GBPOwU8ULCC9MNPt3v8ocrL6tWYt0h5BQw6X7SLi4d5klNo1qHUqB9ptm5Ik/s1600/Top+Down.JPG"><img border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhWaY0KTX8S0t8NEzllL0cMqIZrm_IsAbzxyjalKVKoV1rZ7qqgNRNITjlQr3vZmtnysav9xz3qo09_g1_GBPOwU8ULCC9MNPt3v8ocrL6tWYt0h5BQw6X7SLi4d5klNo1qHUqB9ptm5Ik/s1600/Top+Down.JPG" width="640" /></a><br />The weather is really good, so we decided to take the top off the car for the ride home.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiksXzlI_r6Y_xtfpyw3ml7RtYeKDwhcDEUugclye_13piWBjTTvODmN3eM7szTvYaq_FjKI2DvFrDXk3G3VxGZxnthheFg7_-Gs7GEFzrG5i7PQBlVY-9sFY6H8T9M_m3Ogir5FXB9Bh0/s1600/02+blower.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiksXzlI_r6Y_xtfpyw3ml7RtYeKDwhcDEUugclye_13piWBjTTvODmN3eM7szTvYaq_FjKI2DvFrDXk3G3VxGZxnthheFg7_-Gs7GEFzrG5i7PQBlVY-9sFY6H8T9M_m3Ogir5FXB9Bh0/s1600/02+blower.jpg" height="640" width="444" /></a></div>
Blower and intake filter.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh45_oSsKgMYBa-EP7fiM1xbWSQxgPRMY304FCslwdUsBdtlg3t-3sV2pgGW4hhoen-RdUfqyNnMHn1sxA4VMn-kXR-Jes079f_RkfKIeonl167yPEmNPgsAz-gdv4bj-UwFwtlXF7kzrs/s1600/01+Motor.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;">\</a></div>
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<img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh45_oSsKgMYBa-EP7fiM1xbWSQxgPRMY304FCslwdUsBdtlg3t-3sV2pgGW4hhoen-RdUfqyNnMHn1sxA4VMn-kXR-Jes079f_RkfKIeonl167yPEmNPgsAz-gdv4bj-UwFwtlXF7kzrs/s1600/01+Motor.jpg" height="424" width="640" /></div>
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The motor screen on the commutator side is replaced with a solid band with duct flange. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj-ARNkt2EtBGycXJ_QZXvxDSaPI977dL58vJJ5aBWDfClv0dKvP6b8QWpoEO6WFP_CCP_sOWuuk55RpsxLvVedayBK9R8Za7sE9iXbXWuVhObcs7hYrFW2sa16BwuyGE2ytmkEr6g_150/s1600/03+blower+connection+to+the+motor.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj-ARNkt2EtBGycXJ_QZXvxDSaPI977dL58vJJ5aBWDfClv0dKvP6b8QWpoEO6WFP_CCP_sOWuuk55RpsxLvVedayBK9R8Za7sE9iXbXWuVhObcs7hYrFW2sa16BwuyGE2ytmkEr6g_150/s1600/03+blower+connection+to+the+motor.jpg" height="640" width="424" /></a></div>
Motor and duct, viewed from below. <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhV_HojwDMRlDaT7mssBGHjkFxLIdVQQNrCwNAepbZe3cX2cDHhXxnJHjz2vqdpaEe9lsniEdd4GhBV_jFHZ2KsDfrJYq5ScrDscJ0ED2q-jJBxPtJPPq4K6fzzWfVMidNbKwqLexFpd9I/s1600/04+cytron-dc-motor-controller.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"></a>Now I need a way to control the blower. One option is to use a relay to turn the blower on when the ignition switch is turned on. Another way is to use a programmable speed controller to continuously vary the speed of the blower motor. Guess which option I used? Here is the speed controller: <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEht9GOKrzRp9vGOH3GrwClHiXkm7yy2C3rRQmZeuV4Z-86l8xX-9quDvJRviBNYnRnHkSl22ccR84QvxRgADo5Jfqa81MP5fYPwOl0euXHkvCcgjc51y_UGPdsPYaWkPuJZQ08nfO6cAPY/s1600/04+cytron-dc-motor-controller.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEht9GOKrzRp9vGOH3GrwClHiXkm7yy2C3rRQmZeuV4Z-86l8xX-9quDvJRviBNYnRnHkSl22ccR84QvxRgADo5Jfqa81MP5fYPwOl0euXHkvCcgjc51y_UGPdsPYaWkPuJZQ08nfO6cAPY/s1600/04+cytron-dc-motor-controller.jpg" height="320" width="400" /></a></div>
I need to use a microcontroller to program the speed of the blower speed controller. A microcontroller is a small computer on a chip. It can read signals, do basic math and logic, output 0 to 5 volt signals, and tell time (really). <br />
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The Arduino is connected to the temperature sensor that comes built in to the WarP 9 motor. The sensor is a thermistor – a special resistor that changes resistance as the temperature changes. The Arduino measures the resistance of the thermistor, and I programmed a conversion routine to convert the resistance to temperature based on the curve provided by the thermistor manufacturer. <br />
<br />
The Arduino compares the measured temperature to a target temperature – I selected 120 degrees F as my target – to determine the required fan speed. I’m using a feedback control loop, called PID. The Arduino sends a signal to the blower speed controller. <br />
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I also connected one of my dash gauges to the Arduino. The gauge once displayed oil level, but now will be displaying motor temperature. The Arduino sets the output signal to the transistor to set the gauge needle based on the measured motor temperature. <br />
<br />
My friend Ryan is converting a Volkswagen Beetle to electric. He is going to rig up a similar motor blower for his project. So we took over the kitchen, honed our soldering skills, and turned our ideas into reality. <br />
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I call the result “The Octopus” because there are eight bundles of wires going everywhere. <br />
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I installed the system and took a few test drives to see how everything is working. I plotted motor temperature and blower fan speed for a 15 minute drive. About 5 minutes into the drive, the motor temperature reached 120 degrees F. I programmed the system to wait until blower program speed is at 40% before turning on the blower. The blower doesn’t push much air below this speed. After the 15 minute drive, I let the car sit with the blower running to see how long it would take to cool down. I had been hoping for a little bit more cooling capacity. It looks like the blower will be turning at full speed once the motor reaches 120 degrees. The ambient air temperature that day was 90 degrees. <br />
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<br />Joeyhttp://www.blogger.com/profile/01042435434585986098noreply@blogger.com2tag:blogger.com,1999:blog-3936311651117457138.post-15920033875593125292014-05-09T00:05:00.001-07:002014-05-15T10:35:33.734-07:00Battery Management System - BMS<!--[if gte mso 9]><xml>
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</xml><![endif]-->A battery management system is supposed to help manage the overall health of the battery pack. I have a Lithiumate Lite system by Elithion. Each cell in my pack gets a small circuit board that monitors voltage and temperature. Each board is connected to a master controller that is supposed to take action if any the cells are ever outside the safe voltage range of 2.5 to 3.38 volts. <br />
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The BMS is also designed to maintain all of the cells at the same voltage, when the cells are fully charged, by bleeding off a little bit of charge from the cells with the highest voltage with a shunt resistor. The cells all have slightly different capacity, so they cannot all be at the same voltage all of the time. During discharge, the cells with smaller capacity will reach low voltage before cells with larger capacity. A pack that is at the same voltage when fully charged is top balanced.<br />
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Another common strategy is to make all of the cells have the same voltage when the cells are near empty. This is bottom balancing. Both options have advantages and drawbacks, and unless all of the cells have the exact same capacity and internal electrical properties, you can’t have a battery that is balanced when both full and empty. With a bottom balanced pack, cells survive better if you accidentally over-discharge your pack. However, during charging you have to be extra careful to avoid overcharging your cells. With a top balanced pack, the risks are switched – less problems charging the pack, but if you over-discharge, the first cells to reach the bottom can be damaged by cells that still have significant energy left. <br />
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I decided to disable the active balancing function of my BMS because the active balancing is performed during the charge cycle. The voltage of the cell during charging and discharging will vary quite a bit. You cannot tell how full a cell is by measuring the cell voltage, until the cell has settled for about 24 hours. The good news is that if you manually balance your cells slowly, they tend to stay balanced. I will keep an eye on my cells and see if this holds. So far after nine months, I have not seen any cell drift.<br />
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I lined the inside of my battery boxes with a 1/8" (3 mm) thick rubber exercise mat.<br />
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Each cell gets a small monitoring board that measures voltage and temperature for each cell.<br />
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The pack in the front is wired up. It took about 7 hours to install the cells and BMS. Working with 200 volts slows things down a bit.<br />
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I read a post about someone having communication problems with their BMS. After trying everything they could think of to fix the problem, they finally decided to remove the press-on Molex (bottom row) connectors that came with the BMS, and try the Wago 222 (top row) wire connectors to connect each of the cell boards, and that solved the problem. I really like the Wago connector. The wires are securely locked into place with a lever. About 1 in every 6 Molex connectors I pulled off my system released from the wire with very little effort.Joeyhttp://www.blogger.com/profile/01042435434585986098noreply@blogger.com2tag:blogger.com,1999:blog-3936311651117457138.post-42991024481333942722014-05-08T22:50:00.000-07:002014-05-08T22:50:07.489-07:00Enclosing the Engine Compartment<!--[if gte mso 9]><xml>
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<![endif]-->After seeing the accumulation of road debris that collected in the engine compartment over the last nine months, I realized I have to make an effort to seal up the compartment. I purchased a sheet of 1/8” (3 mm) ABS plastic. I used cardboard to make a template, and then used a jig saw to cut the proper shape. A fine tooth blade and a slow blade speed worked best. Higher speed melted the plastic and caused the cut to reseal.<br />
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I left a gap around the transmission bell housing to allow the motor to move under load. I'm also constructing a panel to enclose the floor of the engine compartment.Joeyhttp://www.blogger.com/profile/01042435434585986098noreply@blogger.com0tag:blogger.com,1999:blog-3936311651117457138.post-73595146365885915172014-04-27T15:08:00.001-07:002014-04-28T15:07:43.827-07:00Painting the Rear Battery RacksThere is a lot of road debris collecting in my motor compartment. Dirt, leaves, and pebbles have accumulated and I realize that a belly pan is not just for aerodynamics. I will need to figure out how to shield the rear motor compartment from the hazards of the road. <br />
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The rust I expected to see – after all there is bound to be some consequence to leaving bare metal to fend for itself in an automotive environment. <br />
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The rust cleaned up well with a bit of sanding and wire brushing. <br />
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Primer and paint always take a long time. Two coats of primer and two more layers of paint, with the work needing to be flipped to get to both sides, waiting for rain to let up, and masking for two colors means 8 days of waiting for paint to dry before I could get the boxes back into the car. <br />
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I struggled to come up with a better way to restrain my cells in the rack and failed to come up with anything better than nylon strapping. Cheap, non-conductive, strong, fast, easy… To prevent chaffing the strap, and to give the boxes a finished look, I found some metal reinforced plastic trim, and pushed it over raw edge of the battery box. <br />
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My upper rack holds 8 cells. To hold the cells securely I used draw latches. I added some standoffs to mount an acrylic cover. Welding is much easier if you remember to attach everything before the paint goes on.<br />
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The boxes blend in below the bumper line much better now that they are finished in flat black paint.<br />
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</xml><![endif]-->I’ve been working on the car nearly every day for the last 5 weeks. I feel like I should have more to show. There are lots of small items in progress and I will report on them as I complete them.<br />
<br />
To paint my battery racks (the front rack is done, the back racks are in progress), I’ve had to take a lot of components out of the car – 60 battery cells, the controller, wiring, and battery charger, not to mention the battery racks themselves. As long as the car was stripped down, I decided to inspect my motor, and it is a good thing I did. I was surprised to find that the brushes were very heavily worn down.<br />
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After doing a little bit of research, it turns out my motor shipped with H49 brushes. H49 are great at transmitting heavy electrical loads but they tend to wear very quickly. Perfect for a drag racing application, but not so good for street use. After 3,500 miles (5,600 km), my brushes were half the original length, or about 80% used up, because you can’t run the brushes all the way down to the embedded pigtail wires. I was expecting to go 50,000 miles (80,000 km) between brush replacements. <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgA0G3g3Ks8qmVYcpoQ8nJO4x02JbbxShBCxopp__SG8PrZO4D81lD4E56RqANBIPjn2wQCWF4OTRguWMP-FiDqIIlxlbMHdev1faHrAsA7uMtnxyh3suBy5VSbcu2XCxUFcDZOqorStU4/s1600/new+brush+old+brush.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgA0G3g3Ks8qmVYcpoQ8nJO4x02JbbxShBCxopp__SG8PrZO4D81lD4E56RqANBIPjn2wQCWF4OTRguWMP-FiDqIIlxlbMHdev1faHrAsA7uMtnxyh3suBy5VSbcu2XCxUFcDZOqorStU4/s1600/new+brush+old+brush.jpg" height="424" width="640" /></a></div>
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New H60 brush on the left. Old H49 brushes in the center and right. I'm not sure why there is uneven wear. A new brush is 1.5 inches (38 mm) long.<span style="mso-spacerun: yes;"> </span></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhDdp-rUtg0qHGk9iRprOg5abwM78FxaLT-0_Af2ilR1eNWvZERDsL5v2UtOED5j3B7H-jcs5cWZUlUABUdkHCCgYBEZ5IF0McGTISQHaVS-hsagnYm0dvRDi3_Rr-nAxYVr54LWymUGQA/s1600/brush+wear.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhDdp-rUtg0qHGk9iRprOg5abwM78FxaLT-0_Af2ilR1eNWvZERDsL5v2UtOED5j3B7H-jcs5cWZUlUABUdkHCCgYBEZ5IF0McGTISQHaVS-hsagnYm0dvRDi3_Rr-nAxYVr54LWymUGQA/s1600/brush+wear.jpg" height="424" width="640" /></a></div>
Here is one of 4 brush holders, with a pair of brushes. The brushes are pressed against the commutator with coil springs.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgU3nnKybfPikgDcdiyuN9wKExi4yS49jFoye1nOCMzl3dynHZ-lZa4x_orcgJc3RMa2iMFdsMbkoY9iQzFUaYP2bukQm2eluCmLae6LR5G-W-xvr9jtSCR5U7-R1Pa930NZsQDdlMnrG0/s1600/commutator+wear.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgU3nnKybfPikgDcdiyuN9wKExi4yS49jFoye1nOCMzl3dynHZ-lZa4x_orcgJc3RMa2iMFdsMbkoY9iQzFUaYP2bukQm2eluCmLae6LR5G-W-xvr9jtSCR5U7-R1Pa930NZsQDdlMnrG0/s1600/commutator+wear.jpg" height="424" width="640" /></a></div>
The brushes have worn shallow grooves in the commutator. This is something I've seen reported by others with the H49 brushes. <br />
<br />
I ordered a set of H60 brushes. The motor takes 8 brushes. These brushes are supposed to be better for street use. They are also supposed to be a little more efficient that the H49 brushes, reportedly around 10%. When new brushes are installed, even though they come preformed with a radius, only a small portion of the brush face is in direct contact with the commutator. The surface of the brush will eventually seat after several hours of run time. The motor will not be capable of full power until the brushes are seated. The motor was run on the bench with a 12 volt battery and charger for 32 hours to accelerate the seating process. <br />
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Also, while the motor was out of the car, I decided to address a small vibration from the motor. At 3,000 rpm I could feel a small vibration in the gear shift knob. The car didn’t vibrate and there was no audible indication of a problem. When I first pulled the gas engine, I took the flywheel to a machine shop for balancing. I should have also brought the clutch disk and pressure plate, to be balanced as an assembly. With just the flywheel, spinning the motor during my brush break-in procedure was vibration free. But when I bolted on the pressure plate, vibration was present above 2000 rpm. The motor spins at about 2400 rpm at 12 volts with no load. The vibration was easily solved by adding extra washers to the pressure plate bolts. Start with a single washer. If the vibration gets worse, move the washer to another position. Once you find the correct position to add mass, keep adding washers until the vibration is gone. I didn’t want a stack of washers all on one bolt. I ended up with one washer each on a grouping of three adjacent bolts. Vibration problem solved. Joeyhttp://www.blogger.com/profile/01042435434585986098noreply@blogger.com0tag:blogger.com,1999:blog-3936311651117457138.post-49734221405878965412014-04-10T00:33:00.000-07:002014-04-27T15:10:04.843-07:00Enhanced Cooling<div class="separator" style="clear: both; text-align: left;">
The Soliton 1 controller can be air or water cooled. When air cooled, the 1000 amp rating of the controller is peak. With a proper cooling loop, the 1000 amp rating is continuous. In warm weather last summer, with air cooling, I experienced thermal cutback. On acceleration, the car feels low on power. A couple times, while climbing a long incline, I had to pull over for 5 minutes and let the fans cool the controller. I’m now installing a radiator, circulation pump, and reservoir for liquid cooling.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh_ORkxNk5Blye55kPd9xeCUltCHHn1SdkaieeQWsk6ff5AXzHfuZtpVD-SPqwtPLPF13FQk4yPhPCeZzGtP-EAFRNXTTXD7aT9WWlkQqiCDxd8E0i1mwjIEjl7Xpt8jg5iEAqwJ-flJnU/s1600/soliton+1.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh_ORkxNk5Blye55kPd9xeCUltCHHn1SdkaieeQWsk6ff5AXzHfuZtpVD-SPqwtPLPF13FQk4yPhPCeZzGtP-EAFRNXTTXD7aT9WWlkQqiCDxd8E0i1mwjIEjl7Xpt8jg5iEAqwJ-flJnU/s1600/soliton+1.jpg" height="281" width="400" /></a></div>
The WarP motor is also air cooled. It has an internal fan that spins with the main motor shaft. I try to operate the motor above 3,000 rpm to maintain a high flow of air through the motor, but the motor is the warmest component after a long drive. I purchased an external blower to increase the flow of air, even when the motor is not spinning.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhPm-uLQ_yoZ8jQTNsh-wVl08uc1shnt3tfJ3lUk2LqUUy9uR6le7h_-U60K_nGTpuQ0KvdOax9tBApWxjFV5tKodjSQ4VRYA2aRZKwjt87SywkdUDY9ldJy0zIM9BlQ40kaMCX5fkpP-k/s1600/blower.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhPm-uLQ_yoZ8jQTNsh-wVl08uc1shnt3tfJ3lUk2LqUUy9uR6le7h_-U60K_nGTpuQ0KvdOax9tBApWxjFV5tKodjSQ4VRYA2aRZKwjt87SywkdUDY9ldJy0zIM9BlQ40kaMCX5fkpP-k/s1600/blower.jpg" height="400" width="278" /></a></div>
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I’m starting to run out of space to place all of my components. I also think that the radiator I purchased is oversized for the job. I determined that the cavity inside the rear bumper is just large enough to fit my cooling components.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi0MnkP22GlAZ9uObsqvZO9NOdtlZjD1Mxx4T73mURyKW5fXfPC4S4MRICu-mNHpoCpSm5Lr5Yz5DNjsgzSKW16VODZNbauT9MnDRXwnOCa_FDFNFMyqPnM25kRG_hU-e0A6SXpES3nV0I/s1600/bare+rack+in+rear+bumper+2.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi0MnkP22GlAZ9uObsqvZO9NOdtlZjD1Mxx4T73mURyKW5fXfPC4S4MRICu-mNHpoCpSm5Lr5Yz5DNjsgzSKW16VODZNbauT9MnDRXwnOCa_FDFNFMyqPnM25kRG_hU-e0A6SXpES3nV0I/s1600/bare+rack+in+rear+bumper+2.jpg" height="424" width="640" /></a></div>
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I started by bolting a few chunks of steel to attachment points on the car. Then I fit a couple of square tube rails parallel to the length of the bumper.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjDZf4W2I9bRkQBHA8rpSgncHbUuPO2BHECDZt8bGUyNrNrTKUGyNCG7mhkPfUCkb4dby771p2skUcm50qVBpD70-KHGtDYUBu9KcFyu6RxRj-01dX6ZKBIkQZO3IZsdfKq_UJiCiJo-I0/s1600/bare+rack+in+rear+bumper.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjDZf4W2I9bRkQBHA8rpSgncHbUuPO2BHECDZt8bGUyNrNrTKUGyNCG7mhkPfUCkb4dby771p2skUcm50qVBpD70-KHGtDYUBu9KcFyu6RxRj-01dX6ZKBIkQZO3IZsdfKq_UJiCiJo-I0/s1600/bare+rack+in+rear+bumper.jpg" height="640" width="478" /></a></div>
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Finally, mounting tabs were added for all of the components: blower, circulation pump, and radiator.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgeEpIu01vtScxpoUm_EUgwf5car97SAe5Iv-A4vl5AyLr9ph36rktE3WOJrsK3heWTBdT9-UOgnJYCxlTRiS8ZzoeLZgk6G_JZGuoRVOmvju-aAFMiY_IxllQ-5wQo6OwSM1glSabMpL0/s1600/bare+frame.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgeEpIu01vtScxpoUm_EUgwf5car97SAe5Iv-A4vl5AyLr9ph36rktE3WOJrsK3heWTBdT9-UOgnJYCxlTRiS8ZzoeLZgk6G_JZGuoRVOmvju-aAFMiY_IxllQ-5wQo6OwSM1glSabMpL0/s1600/bare+frame.jpg" height="240" width="640" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgefaZRNwP-Y5C1SgKaPEhkFZwN1j3zEtYGfA1COZDsqOh2AH6SmHMW3VkcoYZ-Gd3p5Stshyphenhyphen4Y3wqKuIxeJGxV1wluNQsjN5QFURw4-ls1yt3Lc07imV_jrLufL7drnQKdISkelVJfIaU/s1600/populated+rack.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgefaZRNwP-Y5C1SgKaPEhkFZwN1j3zEtYGfA1COZDsqOh2AH6SmHMW3VkcoYZ-Gd3p5Stshyphenhyphen4Y3wqKuIxeJGxV1wluNQsjN5QFURw4-ls1yt3Lc07imV_jrLufL7drnQKdISkelVJfIaU/s1600/populated+rack.jpg" height="264" width="640" /></a></div>
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I'm going to try making a composite fiberglass plug that will fill the gap under the bumper, where the tail pipe once lived.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjb8zY6TTV2PwS770y4pvwPooaV220CL3Py-U3sFr9PRTmIXMgc7lGQAsFObSIQaZbkMrx7-5q-mM2M5rQtBZalvGG2AWxJVZ7Md9HvZ78s5LrrxQsSpLOpNELV7Lqeu0B_ZPafO9_JrHs/s1600/Tailpipe+plug.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjb8zY6TTV2PwS770y4pvwPooaV220CL3Py-U3sFr9PRTmIXMgc7lGQAsFObSIQaZbkMrx7-5q-mM2M5rQtBZalvGG2AWxJVZ7Md9HvZ78s5LrrxQsSpLOpNELV7Lqeu0B_ZPafO9_JrHs/s1600/Tailpipe+plug.jpg" height="424" width="640" /></a></div>
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The result of spending a week of evenings under the car:<br />
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Joeyhttp://www.blogger.com/profile/01042435434585986098noreply@blogger.com0tag:blogger.com,1999:blog-3936311651117457138.post-73595702361388205662014-04-09T09:12:00.000-07:002014-04-09T09:16:01.104-07:00100 CountriesI started the electric Porsche project in December of 2011 and from the beginning I've followed the traffic statistics for this site. I get a report on what keyword searches people used to reach my site, which post they most frequently visit, and the country in which they live. The high water mark for web traffic, with 2,000 hits, occurred in June of 2013, when I took my first electric ride in the car. <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2nWPBPIMXd1VFNqWIddt8p6eTP8_u27fugz4plaVzfidQ8cDZCtnhaIJl5NoOeySwwkuG9siYY24btC2gOCQlF6b_uipm0q1dhDe9pd8Zrm_3jxVnh3juza1-tZLQPE6c2V0JrZX5GEs/s1600/Stats+page.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2nWPBPIMXd1VFNqWIddt8p6eTP8_u27fugz4plaVzfidQ8cDZCtnhaIJl5NoOeySwwkuG9siYY24btC2gOCQlF6b_uipm0q1dhDe9pd8Zrm_3jxVnh3juza1-tZLQPE6c2V0JrZX5GEs/s1600/Stats+page.png" height="640" width="532" /></a></div>
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Just recently I've logged a visit from the 100th country and the honor goes to Mauritius. It's pretty amazing to me that people, literally from around the world are reading about my project. Just for fun, here is the list of all 100 countries, as recognized by the Google servers:<br />
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Joeyhttp://www.blogger.com/profile/01042435434585986098noreply@blogger.com0tag:blogger.com,1999:blog-3936311651117457138.post-67740457452897898272014-03-30T22:41:00.001-07:002014-03-30T22:47:43.340-07:00Painting the Front Battery Rack<div class="separator" style="clear: both; text-align: left;">
I’ve been driving the car for 9 months, and since then, my rate of progress on completing the remaining tasks has virtually halted. A short break to recover from the push to get the car drivable gave way to a longer break to enjoy driving in warm weather with the targa top off. Then, the weather got cold, and I don’t think you are supposed to paint in cold weather. It is time to finish off the last few items on my list.</div>
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The front battery cells are well protected in the front trunk of the 911. The unpainted battery racks looked about the same as they did 9 months ago. And the foam blocks I used to secure the vacuum pump for the brakes look just as bad as they did 9 months ago.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjlnfy7nW5nPlSzAiwhnjT3wJaMbVjq-jfiw28vLcs0PyuVo9ERT6FkZUvLmAR0_uMrrOZ66Tx0NOMXbDhXj2vkZ7K9eEaA4BVdXmDfHINtlQ6xARSJ5TwBzNOvZpnzE2Q50JDT5Klb7KY/s1600/front+rack+before+paint.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjlnfy7nW5nPlSzAiwhnjT3wJaMbVjq-jfiw28vLcs0PyuVo9ERT6FkZUvLmAR0_uMrrOZ66Tx0NOMXbDhXj2vkZ7K9eEaA4BVdXmDfHINtlQ6xARSJ5TwBzNOvZpnzE2Q50JDT5Klb7KY/s1600/front+rack+before+paint.jpg" height="424" width="640" /></a></div>
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With the battery rack out of the way, I was able to properly secure the vacuum reservoir tank and the vacuum pump.</div>
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</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiToiUObeyu39XiST2QCJ6yHvPc5hRBPER9WdSlMKcKR0eZFMx4R4tpWG32NGGCJGeK039l1mf8Uz93rMff2s6U527La09N4HEEmdp16WCXJ_DjYidM5l6LGISKJLTLImaHcRDzPXZvKvU/s1600/pump+and+buffer+mounted.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiToiUObeyu39XiST2QCJ6yHvPc5hRBPER9WdSlMKcKR0eZFMx4R4tpWG32NGGCJGeK039l1mf8Uz93rMff2s6U527La09N4HEEmdp16WCXJ_DjYidM5l6LGISKJLTLImaHcRDzPXZvKvU/s1600/pump+and+buffer+mounted.jpg" height="374" width="640" /></a></div>
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Sanding is one of the most boring activities, but it is a necessary evil to getting a decent paint job. I also added 6 mounting points for installing an acrylic cover over the cell terminals. It seems many people are drawn to touch the battery cells, like moths to a porch light, and while 192 volts is about 300 times less than a Taser, the current can be 100,000 times more – enough to ruin your day. The covers will help people to not touch.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjvzcQUs-OlyoQa0NEuo3bxBE_9ftW2L0CfAi4M-Hl9iNfXI05a0xDBNty6yN83Ja4rtoAKFqmA04emzXY1U5EpEk959UBcWtrz2zpknt5a68dFJoCaC2mgHfj73u4Fl6GqNgKeA3PNDMs/s1600/sanded+and+cover+mounts.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjvzcQUs-OlyoQa0NEuo3bxBE_9ftW2L0CfAi4M-Hl9iNfXI05a0xDBNty6yN83Ja4rtoAKFqmA04emzXY1U5EpEk959UBcWtrz2zpknt5a68dFJoCaC2mgHfj73u4Fl6GqNgKeA3PNDMs/s1600/sanded+and+cover+mounts.jpg" height="520" width="640" /></a></div>
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First coat of primer looks good.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjOFEGn245ubwPZ9lGgmqUCZQM9zBtalWvzK1xs76AzjoZUvqK5HeFruksuBHvWHAMKYlDheoCWptPKVeYp2_2TxaFkoPMgHkXwFB5r2IL5sH_VhhyUgxg9tbzAKwR_-bTaCjcqsvExf7Y/s1600/primer.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjOFEGn245ubwPZ9lGgmqUCZQM9zBtalWvzK1xs76AzjoZUvqK5HeFruksuBHvWHAMKYlDheoCWptPKVeYp2_2TxaFkoPMgHkXwFB5r2IL5sH_VhhyUgxg9tbzAKwR_-bTaCjcqsvExf7Y/s1600/primer.jpg" height="424" width="640" /></a></div>
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I lined the racks with 3 mm thick closed cell foam.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi4eTkSAFkdy75d9RWPONS2Puxj54bpGM53j_Sg-VmS9sDomx4fyKZNi_6lBpEpxyCNwcDmi-pnUJFqhIFM7uX_PdFaXOu1uSsI3Db6K7fK-XFZG4ZgigkpFzAe-j398k8pLgcvVAdpx_E/s1600/front+rack+reinstalled.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi4eTkSAFkdy75d9RWPONS2Puxj54bpGM53j_Sg-VmS9sDomx4fyKZNi_6lBpEpxyCNwcDmi-pnUJFqhIFM7uX_PdFaXOu1uSsI3Db6K7fK-XFZG4ZgigkpFzAe-j398k8pLgcvVAdpx_E/s1600/front+rack+reinstalled.jpg" height="424" width="640" /></a></div>
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The cells look good, securely mounted in the newly painted rack.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhCaykJ7vOBZiFE6e1twJY4DrOTLwPlr57kJWi5CBnz0XVTbbzCbYteG-qSBOC9lVPPd1X0M_8Os7mhenIhA3LCQp7qPu0q_Ze6s89ZffuTvhzfDRxdez9y7Y1JnM27vGCWbmPVoykXs0Q/s1600/painted+rack.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhCaykJ7vOBZiFE6e1twJY4DrOTLwPlr57kJWi5CBnz0XVTbbzCbYteG-qSBOC9lVPPd1X0M_8Os7mhenIhA3LCQp7qPu0q_Ze6s89ZffuTvhzfDRxdez9y7Y1JnM27vGCWbmPVoykXs0Q/s1600/painted+rack.jpg" height="364" width="640" /></a></div>
Joeyhttp://www.blogger.com/profile/01042435434585986098noreply@blogger.com0tag:blogger.com,1999:blog-3936311651117457138.post-18741482074961079052013-11-26T17:36:00.001-08:002013-11-27T08:36:18.464-08:00Registration and Taxes<!--[if gte mso 9]><xml>
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I purchased the 911, in gas form, nearly two years ago.<span style="mso-spacerun: yes;"> </span>The registration expires next
month. Most gas vehicles where I live have to pass a vehicle emissions test as
a condition for registration renewal.<span style="mso-spacerun: yes;"> </span>By registering
the car as an electric powered vehicle, I will be exempt from the emissions
testing.<span style="mso-spacerun: yes;"> </span>I’ve heard countless tales of
bureaucratic confusion surrounding the process of registering a vehicle that
has been converted to run on electricity.<span style="mso-spacerun: yes;">
</span>I was expecting and prepared for an ordeal.<span style="mso-spacerun: yes;"> </span>Fifteen minutes after stepping into the
department of motor vehicles office, my car was registered with the state of
Oregon as an electric powered vehicle.<span style="mso-spacerun: yes;">
</span>The whole event took a little extra time because the clerk was so skeptical
that the process could actually be so painless that she called her supervisor over to
confirm that there was no inspection, documentation, extra fees, sworn and notarized
affidavit, or clearance from a mental health professional required to complete
the transaction.<span style="mso-spacerun: yes;"> </span>There was just a simple
change made to the database under fuel type: electric.</div>
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<br /></div>
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The supervisor commented that he was aware that a number of people
have installed fork lift motors on small pick-up trucks, like the Chevy S-10
and the Ford Ranger, but never on a vehicle that was nice, like a Porsche.<span style="mso-spacerun: yes;"> </span>The public perception of converted electric
vehicles is still dominated by anemic lead acid powered examples. <span style="mso-spacerun: yes;"> </span>Without knowing that lithium technology is now
viable, the concept of an electric sports car conversion would be incongruent.<span style="mso-spacerun: yes;"> </span>My goal that day was to walk out of the
office with registration stickers, and everything was going smoothly, so I didn’t
feel it was the proper time and place to explain that electric cars have changed and that my conversion could
outperform the stock gas configuration.<span style="mso-spacerun: yes;"> </span>The
phrase, “Anything you say can be used against you…” was on my mind.</div>
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<span style="mso-spacerun: yes;"> </span> </div>
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After confirming that I was now exempted from pollution
testing, the clerk commented that I would also not be paying gas taxes, a tacit admonition that driving on public roads without paying the gas tax is dishonorable. </div>
<div class="MsoNormal">
<br /></div>
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<span style="mso-spacerun: yes;"> </span>Oregon
was the first state in the United States to enact a fuel tax, back in 1919,
with the revenue to be used for building and maintaining the road system.<span style="mso-spacerun: yes;"> </span>I believe a road is a public good, and I support
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</span>I also support a tax based on fuel consumption, because it creates an
incentive to consume less fuel and produce less pollution.<span style="mso-spacerun: yes;"> </span>As the average fuel efficiency of road going
vehicles has increased over the years, and people are buying less fuel, the fuel tax revenue has been declining.<span style="mso-spacerun: yes;"> </span>
</div>
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<br /></div>
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And so I wondered, just how much tax was I avoiding by
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state of Oregon collected $1,394,000,000 USD for maintaining and building
roads and <span style="mso-spacerun: yes;"></span>13% of that total was derived
from the fuel tax.<span style="mso-spacerun: yes;"> </span>I’m still participating
in the other 87% of the revenue generating categories, so I’m OK with not
paying the gas tax and still using the public roads.<span style="mso-spacerun: yes;"> </span></div>
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<br /></div>
<div class="MsoNormal">
Here is how the rest of the
road funds in Oregon are sourced: 37% from the federal government, 25% from
bonds, and 13% from vehicle and motor carrier (commercial) fees.<span style="mso-spacerun: yes;"> </span>The remaining funds come from local sources,
and an official sounding category – miscellaneous.</div>
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<br /></div>
<div class="MsoNormal">
(Source: U.S. Department of Transportation- Federal Highway
Administration: “Revenues Used by States on Highways”: 2009;<a href="http://www.fhwa.dot.gov/policyinformation/statistics/2009/sf3.cfm" target="_blank"> http://www.fhwa.dot.gov/policyinformation/statistics/2009/sf3.cfm</a>)<span style="mso-spacerun: yes;"> </span></div>
Joeyhttp://www.blogger.com/profile/01042435434585986098noreply@blogger.com2tag:blogger.com,1999:blog-3936311651117457138.post-59880301665677572072013-08-28T23:26:00.000-07:002013-08-28T23:36:14.256-07:00Wheel Alignment and Weight Distribution<!--[if gte mso 9]><xml>
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</xml><![endif]-->I can’t say enough good things about <a href="http://rothsport-racing.com/" target="_blank">Rothsport Racing</a>, an automotive shop in Tualatin, Oregon specializing in Porsche. I took the car in to get an alignment after switching to stiffer torsion bars. The shop was great. There were six car up on lifts, a machine shop, and several 911s, some set up for full racing. I was a little apprehensive bringing an electric Porsche to a Porsche racing shop, because I wasn’t sure how the car would be received. Jeff Gamroth, the proprietor, introduced himself, and after a quick show and tell, we took the car for a quick spin down the street. He liked the torque, but said the lack of engine noise was strange. We then pulled the car around into the shop bay, and five mechanics immediately flocked to the car. The silent entrance certainly got everyone’s attention. “Was that you guys? We heard a strange sound going down the street.” Everyone seemed OK with the electric modifications, or at least kept their horror in check. There were lots of questions about the batteries, range, safety advice to avoid electrocution while working on the car, and for the first time someone noticed my tachometer sensor mounted on the electric motor tail shaft. One of the guys joked, “At least you didn’t bolt on an LS2,” a jab at the practice of installing a Chevy Corvette V8 motor in a 911. <br />
<br />
The alignment did wonders for the handling of the car. The steering is lighter and more precise. As a bonus, they also put the car on a scale. My conversion tips the scale at 3158 pounds (1432 kg), and is 408 pounds (185 kg) over stock. The front is heavier by 231 lbs and the back 177 lbs, shifting the front/back weight distribution from 38/62 to 40/60.Joeyhttp://www.blogger.com/profile/01042435434585986098noreply@blogger.com0tag:blogger.com,1999:blog-3936311651117457138.post-6163020761216909052013-07-26T11:09:00.002-07:002013-07-26T11:09:36.925-07:001000 Miles, 1000 Amps<div class="separator" style="clear: both; text-align: center;">
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</xml><![endif]-->I recently logged my first 1,000 EV miles. It was time to bump the Soliton 1 controller to the maximum setting of (cue the sinister movie sound clip) – 1,000 amps. There are a couple reasons to begin with a low current and ramp up to greater performance over time. While testing out the new EV system, a low current setting will minimize damage, if there is a problem. Another reason is I’m using a motor with brushes. <br /><br />When a DC motor is new, the brushes do not make full contact with the commutator. Small imperfections in the contour radius at the brush and commutator interface increase the electrical impendence of the motor. If you try to pass a lot of current through new brushes, the motor is at risk of arcing and overheating. On the bench, I ran the motor for 30 hours at 12 volts. Then, when first installed into the car, the gradual increase in motor current allowed the brushes to properly seat as the high points on the brush get worn away. <br /><br />With the 1000 amp limit, the difference in performance is significant and amazing. The extra 40 kilowatts of power (50 HP), relative to 600 amps, makes the car fly. The stock 3.0 liter internal combustion engine (ICE) output was rated 127 kW (170 HP). As an electric conversion, I recently logged a run on my commute to work with a current draw of 890 amps producing 120 kW of power (160 HP).<span style="mso-spacerun: yes;"> </span>
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<![endif]-->The logged run did 0 to 60 MPH in 9 seconds. I started in 2nd gear and at 5.7 seconds I shifted to 3rd. The 0 to 40 time was 4 seconds. If I open up my motor RPM limit to 5,500 I can reach 60 MPH in second gear and avoid the 2 second penalty of shifting. 2 seconds is a long shift, but I’m still getting used to this gearbox and after 97,000 ICE miles, the synchro-mesh is not in best form . The car seems to be on par with the stock performance, especially given that with the electric motor, peak torque is available between 0 and 5,000 rpm. I need to find an open bit of road with no traffic and see what happens when I push the full 1,000 amps.<br /> <span style="font-family: "Calibri","sans-serif"; font-size: 11.0pt; line-height: 115%; mso-ansi-language: EN-US; mso-ascii-theme-font: minor-latin; mso-bidi-font-family: "Times New Roman"; mso-bidi-language: AR-SA; mso-bidi-theme-font: minor-bidi; mso-fareast-font-family: Calibri; mso-fareast-language: EN-US; mso-fareast-theme-font: minor-latin; mso-hansi-theme-font: minor-latin;"><br style="mso-special-character: line-break;" />
</span>Joeyhttp://www.blogger.com/profile/01042435434585986098noreply@blogger.com5tag:blogger.com,1999:blog-3936311651117457138.post-54643918013940161792013-07-22T21:37:00.000-07:002013-07-22T21:37:31.369-07:00Celebrate Hillsboro and Another Video<div class="separator" style="clear: both; text-align: center;">
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<![endif]-->I had the car on display at a local event called Celebrate Hillsboro – a city festival with music, kids activities, sports, bicycle rides, and a farmers’ market. My car was positioned in the intersection right in the middle of the event. The car generated a lot of positive attention. </div>
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</xml><![endif]-->A few people expressed disappointment in my choice of donor. Some were misinformed on the performance capability of electric drive and others were dismayed that I messed with a classic. But the response was overwhelmingly positive. I even met a few people that are currently converting their own vehicles. By far the most common questions I get are range, cost and battery life (100 miles, a lot, and 3000 cycles). <br /><br />I’ve received a lot of requests for another video. I’m pleased that the controller in quiet mode no longer generates that obnoxious 8 kHz switching buzz.<br />
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Joeyhttp://www.blogger.com/profile/01042435434585986098noreply@blogger.com16tag:blogger.com,1999:blog-3936311651117457138.post-80702654899013988732013-07-15T00:31:00.000-07:002013-07-15T15:56:54.326-07:00EV Celebration Day, part 2<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiN796wGqViVuvozj9vkA1AvyNT3rJokvqWbyKyIQBumAIWsDwvJlseZdg7hJToFWtX0M_0rvJq9B6jyl11YQO1YI9zH522lCzrp5eBE4mguSGUp3KY38oXX_qb0uksL15ZDMDxL5-jfMo/s1600/EV+Day+Banner+-+patrick+connor.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="356" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiN796wGqViVuvozj9vkA1AvyNT3rJokvqWbyKyIQBumAIWsDwvJlseZdg7hJToFWtX0M_0rvJq9B6jyl11YQO1YI9zH522lCzrp5eBE4mguSGUp3KY38oXX_qb0uksL15ZDMDxL5-jfMo/s640/EV+Day+Banner+-+patrick+connor.jpg" width="640" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;"><span data-ft="{"tn":"K"}" data-reactid=".r[1dgr1].[1][4][1]{replies10151606970903020_26887644}.[1][2]{comment10151606970903020_26888933}.[0].[right].[0].[left].[0].[0].[0][2]"><span data-reactid=".r[1dgr1].[1][4][1]{replies10151606970903020_26887644}.[1][2]{comment10151606970903020_26888933}.[0].[right].[0].[left].[0].[0].[0][2].[0]"><span data-reactid=".r[1dgr1].[1][4][1]{replies10151606970903020_26887644}.[1][2]{comment10151606970903020_26888933}.[0].[right].[0].[left].[0].[0].[0][2].[0].[0]">Photograph by Patrick Connor @ oeva.org</span></span></span></td></tr>
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</xml><![endif]-->We filled Portland’s Pioneer Courthouse Square with electric cars – both commercial vehicles and electric conversions. A large crowd turned out and the weather was perfect. Overall it was a really good event. I was impressed that the general public’s awareness of electric vehicles has gone up over the last 10 years. <br />
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<tr><td class="tr-caption" style="text-align: center;"><span data-ft="{"tn":"K"}" data-reactid=".r[1dgr1].[1][4][1]{replies10151606970903020_26887644}.[1][2]{comment10151606970903020_26888933}.[0].[right].[0].[left].[0].[0].[0][2]"><span data-reactid=".r[1dgr1].[1][4][1]{replies10151606970903020_26887644}.[1][2]{comment10151606970903020_26888933}.[0].[right].[0].[left].[0].[0].[0][2].[0]"><span data-reactid=".r[1dgr1].[1][4][1]{replies10151606970903020_26887644}.[1][2]{comment10151606970903020_26888933}.[0].[right].[0].[left].[0].[0].[0][2].[0].[0]">From left to right - Toyota Corolla, Porsche 911, Nissan Leaf, Tesla Model S, truck conversion. Photograph by Bill Bates.</span></span></span></td></tr>
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<tr><td class="tr-caption" style="text-align: center;">Pride in ownership.</td></tr>
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjTD9FOOHn16s21p0tBdgypOKdHVR3Frsvm3xhWGMdw_fnby08ppvwxqTVfzLFPVkCY78PejiCf0a-pK37O3WcZzEneacp0Zx6XkXSOyl3xeYqpprlCh_dULJGuEk-MWd5VoRMyQ7foBfs/s1600/Crowds+at+the+Show+-+Bill+Bates-1.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="426" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjTD9FOOHn16s21p0tBdgypOKdHVR3Frsvm3xhWGMdw_fnby08ppvwxqTVfzLFPVkCY78PejiCf0a-pK37O3WcZzEneacp0Zx6XkXSOyl3xeYqpprlCh_dULJGuEk-MWd5VoRMyQ7foBfs/s640/Crowds+at+the+Show+-+Bill+Bates-1.jpg" width="640" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;"><span data-ft="{"tn":"K"}" data-reactid=".r[1dgr1].[1][4][1]{replies10151606970903020_26887644}.[1][2]{comment10151606970903020_26888933}.[0].[right].[0].[left].[0].[0].[0][2]"><span data-reactid=".r[1dgr1].[1][4][1]{replies10151606970903020_26887644}.[1][2]{comment10151606970903020_26888933}.[0].[right].[0].[left].[0].[0].[0][2].[0]"><span data-reactid=".r[1dgr1].[1][4][1]{replies10151606970903020_26887644}.[1][2]{comment10151606970903020_26888933}.[0].[right].[0].[left].[0].[0].[0][2].[0].[0]">There was a steady stream of visitors all day long. Photograph by Bill Bates.</span></span></span></td><td class="tr-caption" style="text-align: center;"></td><td class="tr-caption" style="text-align: center;"></td><td class="tr-caption" style="text-align: center;"></td><td class="tr-caption" style="text-align: center;"><span data-ft="{"tn":"K"}" data-reactid=".r[1dgr1].[1][4][1]{replies10151606970903020_26887644}.[1][2]{comment10151606970903020_26888933}.[0].[right].[0].[left].[0].[0].[0][2]"><span data-reactid=".r[1dgr1].[1][4][1]{replies10151606970903020_26887644}.[1][2]{comment10151606970903020_26888933}.[0].[right].[0].[left].[0].[0].[0][2].[0]"><span data-reactid=".r[1dgr1].[1][4][1]{replies10151606970903020_26887644}.[1][2]{comment10151606970903020_26888933}.[0].[right].[0].[left].[0].[0].[0][2].[0].[0]"></span></span></span><br /></td><td class="tr-caption" style="text-align: center;"><span data-ft="{"tn":"K"}" data-reactid=".r[1dgr1].[1][4][1]{replies10151606970903020_26887644}.[1][2]{comment10151606970903020_26888933}.[0].[right].[0].[left].[0].[0].[0][2]"><span data-reactid=".r[1dgr1].[1][4][1]{replies10151606970903020_26887644}.[1][2]{comment10151606970903020_26888933}.[0].[right].[0].[left].[0].[0].[0][2].[0]"><span data-reactid=".r[1dgr1].[1][4][1]{replies10151606970903020_26887644}.[1][2]{comment10151606970903020_26888933}.[0].[right].[0].[left].[0].[0].[0][2].[0].[0]"></span></span></span><br /></td><td class="tr-caption" style="text-align: center;"></td></tr>
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I spent the entire day answering questions about my car, and the response was overwhelmingly positive. <br /><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgUWbFjo2LXyL-wDTs8bCBw2Uf5atX4IDNqoKuM6LlwMfo8norohyOsFkHz5vWBGrLht4itDwBmMX22X_fZPqRkE3jqNS3pz_HnhSbEiFiqkledhZfI47vNEm-8bAvWExJScxVoccskroI/s1600/Talking+with+the+Public.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgUWbFjo2LXyL-wDTs8bCBw2Uf5atX4IDNqoKuM6LlwMfo8norohyOsFkHz5vWBGrLht4itDwBmMX22X_fZPqRkE3jqNS3pz_HnhSbEiFiqkledhZfI47vNEm-8bAvWExJScxVoccskroI/s640/Talking+with+the+Public.jpg" width="640" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Discussing the finer points of AC vs DC motors, and the price of lithium.</td></tr>
</tbody></table>
One of the highlights for me was chatting with a member of the <a href="http://groups.oregonstate.edu/solar/" target="_blank">Oregon State University solar racing team</a>, fresh off their first place finish at the 2013 Formula Sun Grand Prix.
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhO4lwGqqWrLrg0ITABDpSM8IFKrUbUIjYh8cwyENGJPVFBSNayR1-ZZ9LMpvEW7T8JXuMYVZkO-WMG493AxLJeIwK6UeDuOXx150JSWEuTt7cq29hJDMPM1RUwCAzHkV0ywruavMsEKU4/s1600/OSU+Racer-1.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="424" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhO4lwGqqWrLrg0ITABDpSM8IFKrUbUIjYh8cwyENGJPVFBSNayR1-ZZ9LMpvEW7T8JXuMYVZkO-WMG493AxLJeIwK6UeDuOXx150JSWEuTt7cq29hJDMPM1RUwCAzHkV0ywruavMsEKU4/s640/OSU+Racer-1.jpg" width="640" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Oregon State University solar race car. </td><td class="tr-caption" style="text-align: center;"></td><td class="tr-caption" style="text-align: center;"></td><td class="tr-caption" style="text-align: center;"><br /></td><td class="tr-caption" style="text-align: center;"><br /></td><td class="tr-caption" style="text-align: center;"><br /></td><td class="tr-caption" style="text-align: center;"><br /></td></tr>
</tbody></table>
<br />
John Wayland, electric drag racing pioneer and owner of the <a href="http://www.plasmaboyracing.com/whitezombie.php" target="_blank">fastest street legal electric drag car</a> in the world, introduced himself and shared some wild adventures of when he owned a Porsche 911 SC. He says that the Zombie’s times are going to drop into the 9 second range for the ¼ mile. <br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh1GjGFdNFkEbQtRepeZvWWtSCXvMLf45eb1JealpBJLrrGb0gB1JMLOjXPgOFppJnUt2sHmcrRU2Vklgq3pK7gDz3DX5IBl1WYjjBvS2jCM3WM28gUwaILvNHTcgb_p_axkBDdZwQL-8s/s1600/Zombie+-+patrick+connor.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="468" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh1GjGFdNFkEbQtRepeZvWWtSCXvMLf45eb1JealpBJLrrGb0gB1JMLOjXPgOFppJnUt2sHmcrRU2Vklgq3pK7gDz3DX5IBl1WYjjBvS2jCM3WM28gUwaILvNHTcgb_p_axkBDdZwQL-8s/s640/Zombie+-+patrick+connor.jpg" width="640" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;"><span data-ft="{"tn":"K"}" data-reactid=".r[1dgr1].[1][4][1]{replies10151606970903020_26887644}.[1][2]{comment10151606970903020_26888933}.[0].[right].[0].[left].[0].[0].[0][2]"><span data-reactid=".r[1dgr1].[1][4][1]{replies10151606970903020_26887644}.[1][2]{comment10151606970903020_26888933}.[0].[right].[0].[left].[0].[0].[0][2].[0]"><span data-reactid=".r[1dgr1].[1][4][1]{replies10151606970903020_26887644}.[1][2]{comment10151606970903020_26888933}.[0].[right].[0].[left].[0].[0].[0][2].[0].[0]">White Zombie is a 1972 Datsun that has been modified to go fast. Photograph by Patrick Connor @ oeva.org</span></span></span></td><td class="tr-caption" style="text-align: center;"></td><td class="tr-caption" style="text-align: center;"></td><td class="tr-caption" style="text-align: center;"></td><td class="tr-caption" style="text-align: center;"></td></tr>
</tbody></table>
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg6ak3uvyQj28shhdH0LnWqtygtHCDgl2g8KKUtjtT8HxGVS8ahuKt8ebxTeqlgSy8XUzUd95dYhq57KJ1A9iHHVLtNAOqpGnEYcgtQ4qaQZVJTD5fReVQQDC-pCXo-0FytM65N9vfkpYo/s1600/Zombie+under+the+hood+-+patrick+connor.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="426" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg6ak3uvyQj28shhdH0LnWqtygtHCDgl2g8KKUtjtT8HxGVS8ahuKt8ebxTeqlgSy8XUzUd95dYhq57KJ1A9iHHVLtNAOqpGnEYcgtQ4qaQZVJTD5fReVQQDC-pCXo-0FytM65N9vfkpYo/s640/Zombie+under+the+hood+-+patrick+connor.jpg" width="640" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;"><span data-ft="{"tn":"K"}" data-reactid=".r[1dgr1].[1][4][1]{replies10151606970903020_26887644}.[1][2]{comment10151606970903020_26888933}.[0].[right].[0].[left].[0].[0].[0][2]"><span data-reactid=".r[1dgr1].[1][4][1]{replies10151606970903020_26887644}.[1][2]{comment10151606970903020_26888933}.[0].[right].[0].[left].[0].[0].[0][2].[0]"><span data-reactid=".r[1dgr1].[1][4][1]{replies10151606970903020_26887644}.[1][2]{comment10151606970903020_26888933}.[0].[right].[0].[left].[0].[0].[0][2].[0].[0]">Twin 9 inch motors and low mass are part of the White Zombie go fast equation. </span></span></span><br />
<span data-ft="{"tn":"K"}" data-reactid=".r[1dgr1].[1][4][1]{replies10151606970903020_26887644}.[1][2]{comment10151606970903020_26888933}.[0].[right].[0].[left].[0].[0].[0][2]"><span data-reactid=".r[1dgr1].[1][4][1]{replies10151606970903020_26887644}.[1][2]{comment10151606970903020_26888933}.[0].[right].[0].[left].[0].[0].[0][2].[0]"><span data-reactid=".r[1dgr1].[1][4][1]{replies10151606970903020_26887644}.[1][2]{comment10151606970903020_26888933}.[0].[right].[0].[left].[0].[0].[0][2].[0].[0]">Photograph by Patrick Connor @ oeva.org</span></span></span></td></tr>
</tbody></table>
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjBhr1xp2f_78b1-1xsjJoMybzG10VAs5PucoQSLp8FKDz5yIEjfJxVa445ebluHoB1ETHeuELE-qOOp-MM5tYJH5a-KKdsWUsqktZDPAWbqCVM4WvzlwccAXZzRvjdGurPkQsTrzM9PyI/s1600/Electric+VW+bus+profile+-+patrick+connor.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="476" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjBhr1xp2f_78b1-1xsjJoMybzG10VAs5PucoQSLp8FKDz5yIEjfJxVa445ebluHoB1ETHeuELE-qOOp-MM5tYJH5a-KKdsWUsqktZDPAWbqCVM4WvzlwccAXZzRvjdGurPkQsTrzM9PyI/s640/Electric+VW+bus+profile+-+patrick+connor.jpg" width="640" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;"><span data-ft="{"tn":"K"}" data-reactid=".r[1dgr1].[1][4][1]{replies10151606970903020_26887644}.[1][2]{comment10151606970903020_26888933}.[0].[right].[0].[left].[0].[0].[0][2]"><span data-reactid=".r[1dgr1].[1][4][1]{replies10151606970903020_26887644}.[1][2]{comment10151606970903020_26888933}.[0].[right].[0].[left].[0].[0].[0][2].[0]"><span data-reactid=".r[1dgr1].[1][4][1]{replies10151606970903020_26887644}.[1][2]{comment10151606970903020_26888933}.[0].[right].[0].[left].[0].[0].[0][2].[0].[0]">This electric VW bus conversion is beautiful. Photograph by Patrick Connor @ oeva.org</span></span></span></td></tr>
</tbody></table>
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiD0X6csf3Y0IEFVMFtpnNNAMiWhMFZCTMZh7rZqZYhINzZPaelHWSaR141LzCpXlBxllp0rB3h-bABiKUgg0bsHqJeyDxDbdk00f0Ry0ao5oEtZoo2Z1KlIRg57t3Xqa636EwTnkYIJBk/s1600/Electric+VW+bus+-+patrick+connor.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="426" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiD0X6csf3Y0IEFVMFtpnNNAMiWhMFZCTMZh7rZqZYhINzZPaelHWSaR141LzCpXlBxllp0rB3h-bABiKUgg0bsHqJeyDxDbdk00f0Ry0ao5oEtZoo2Z1KlIRg57t3Xqa636EwTnkYIJBk/s640/Electric+VW+bus+-+patrick+connor.jpg" width="640" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;"><span data-ft="{"tn":"K"}" data-reactid=".r[1dgr1].[1][4][1]{replies10151606970903020_26887644}.[1][2]{comment10151606970903020_26888933}.[0].[right].[0].[left].[0].[0].[0][2]"><span data-reactid=".r[1dgr1].[1][4][1]{replies10151606970903020_26887644}.[1][2]{comment10151606970903020_26888933}.[0].[right].[0].[left].[0].[0].[0][2].[0]"><span data-reactid=".r[1dgr1].[1][4][1]{replies10151606970903020_26887644}.[1][2]{comment10151606970903020_26888933}.[0].[right].[0].[left].[0].[0].[0][2].[0].[0]">I love that the motor mount and motor face are exposed. Truly a work of art. Photograph by Patrick Connor @ oeva.org</span></span></span></td></tr>
</tbody></table>
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg3jwgzvxtFz_Bx27H0mh23ski974q-zNR-b8CVB0_whultvui89AmaECYb93pA7R0kffIqqorwcUqad6T-gMxS1Hvt222bZX2sx_PO3BnuSDI1g0jBxuJNqQ-qJqSH5AqfZw1icFKDRME/s1600/electric+bug+and+electric+bicycle+-+patrick+connor.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="426" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg3jwgzvxtFz_Bx27H0mh23ski974q-zNR-b8CVB0_whultvui89AmaECYb93pA7R0kffIqqorwcUqad6T-gMxS1Hvt222bZX2sx_PO3BnuSDI1g0jBxuJNqQ-qJqSH5AqfZw1icFKDRME/s640/electric+bug+and+electric+bicycle+-+patrick+connor.jpg" width="640" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;"><span data-ft="{"tn":"K"}" data-reactid=".r[1dgr1].[1][4][1]{replies10151606970903020_26887644}.[1][2]{comment10151606970903020_26888933}.[0].[right].[0].[left].[0].[0].[0][2]"><span data-reactid=".r[1dgr1].[1][4][1]{replies10151606970903020_26887644}.[1][2]{comment10151606970903020_26888933}.[0].[right].[0].[left].[0].[0].[0][2].[0]"><span data-reactid=".r[1dgr1].[1][4][1]{replies10151606970903020_26887644}.[1][2]{comment10151606970903020_26888933}.[0].[right].[0].[left].[0].[0].[0][2].[0].[0]">Electric bug and electric bicycle. Photograph by Patrick Connor @ oeva.org</span></span></span></td></tr>
</tbody></table>
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihN1QE_n1Z68SYqXetcH7mHDW_33QftPF3bCGh_WIVGZoIEzLUJ9EPc1L9tjAK8Oq0FrhBzdKNZcnml0h_Fh-_ngyjE439rsqAk7znnVGXSSKZVVXOIGf3-wAurH9bQKBUlsYGu9gEaqs/s1600/Model+S+-+patrick+connor.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="426" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihN1QE_n1Z68SYqXetcH7mHDW_33QftPF3bCGh_WIVGZoIEzLUJ9EPc1L9tjAK8Oq0FrhBzdKNZcnml0h_Fh-_ngyjE439rsqAk7znnVGXSSKZVVXOIGf3-wAurH9bQKBUlsYGu9gEaqs/s640/Model+S+-+patrick+connor.jpg" width="640" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;"><span data-ft="{"tn":"K"}" data-reactid=".r[1dgr1].[1][4][1]{replies10151606970903020_26887644}.[1][2]{comment10151606970903020_26888933}.[0].[right].[0].[left].[0].[0].[0][2]"><span data-reactid=".r[1dgr1].[1][4][1]{replies10151606970903020_26887644}.[1][2]{comment10151606970903020_26888933}.[0].[right].[0].[left].[0].[0].[0][2].[0]"><span data-reactid=".r[1dgr1].[1][4][1]{replies10151606970903020_26887644}.[1][2]{comment10151606970903020_26888933}.[0].[right].[0].[left].[0].[0].[0][2].[0].[0]">Everyone loves the Tesla Model S. Photograph by Patrick Connor @ oeva.org</span></span></span></td></tr>
</tbody></table>
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiB-2OmBhDFlH2M1_6iVk8X8XcP4uoZ-kuoxbcsBw29YgxfgLn24CfdgIgUg-46aImqLZB70bJA6TJjkTChXds977NRR6V-KymCMVtHz7x3U7Uejai8-quObBziGHOcilqAijOZL3yKkas/s1600/Some+sort+of+electric+vehicles+with+2+wheels.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="426" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiB-2OmBhDFlH2M1_6iVk8X8XcP4uoZ-kuoxbcsBw29YgxfgLn24CfdgIgUg-46aImqLZB70bJA6TJjkTChXds977NRR6V-KymCMVtHz7x3U7Uejai8-quObBziGHOcilqAijOZL3yKkas/s640/Some+sort+of+electric+vehicles+with+2+wheels.jpg" width="640" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;"><span data-ft="{"tn":"K"}" data-reactid=".r[1dgr1].[1][4][1]{replies10151606970903020_26887644}.[1][2]{comment10151606970903020_26888933}.[0].[right].[0].[left].[0].[0].[0][2]"><span data-reactid=".r[1dgr1].[1][4][1]{replies10151606970903020_26887644}.[1][2]{comment10151606970903020_26888933}.[0].[right].[0].[left].[0].[0].[0][2].[0]"><span data-reactid=".r[1dgr1].[1][4][1]{replies10151606970903020_26887644}.[1][2]{comment10151606970903020_26888933}.[0].[right].[0].[left].[0].[0].[0][2].[0].[0]">Some electric vehicles with only two wheels. Photograph by Patrick Connor @ oeva.org</span></span></span></td></tr>
</tbody></table>
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiooLFiJxQHnst7FFhwLIG3kk0RxRt1fHv4tt5QcILF05vZK0oKgL9eP9NgPzrWEHysjX7Hk2YmWdp5kBN1oVTTQOhZIBoJLHDzdm8jFtzvA3wruGWoQWn0uvy09LA8R3-irKNpDlvo1t4/s1600/TH!NK+city+-+patrick+connor.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="380" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiooLFiJxQHnst7FFhwLIG3kk0RxRt1fHv4tt5QcILF05vZK0oKgL9eP9NgPzrWEHysjX7Hk2YmWdp5kBN1oVTTQOhZIBoJLHDzdm8jFtzvA3wruGWoQWn0uvy09LA8R3-irKNpDlvo1t4/s640/TH!NK+city+-+patrick+connor.jpg" width="640" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;"><span data-ft="{"tn":"K"}" data-reactid=".r[1dgr1].[1][4][1]{replies10151606970903020_26887644}.[1][2]{comment10151606970903020_26888933}.[0].[right].[0].[left].[0].[0].[0][2]"><span data-reactid=".r[1dgr1].[1][4][1]{replies10151606970903020_26887644}.[1][2]{comment10151606970903020_26888933}.[0].[right].[0].[left].[0].[0].[0][2].[0]"><span data-reactid=".r[1dgr1].[1][4][1]{replies10151606970903020_26887644}.[1][2]{comment10151606970903020_26888933}.[0].[right].[0].[left].[0].[0].[0][2].[0].[0]">The TH!NK city (red and black) are cute cars. Too bad they are not currently in production.</span></span></span><br />
<span data-ft="{"tn":"K"}" data-reactid=".r[1dgr1].[1][4][1]{replies10151606970903020_26887644}.[1][2]{comment10151606970903020_26888933}.[0].[right].[0].[left].[0].[0].[0][2]"><span data-reactid=".r[1dgr1].[1][4][1]{replies10151606970903020_26887644}.[1][2]{comment10151606970903020_26888933}.[0].[right].[0].[left].[0].[0].[0][2].[0]"><span data-reactid=".r[1dgr1].[1][4][1]{replies10151606970903020_26887644}.[1][2]{comment10151606970903020_26888933}.[0].[right].[0].[left].[0].[0].[0][2].[0].[0]">Photograph by Patrick Connor @ oeva.org</span></span></span></td></tr>
</tbody></table>
Joeyhttp://www.blogger.com/profile/01042435434585986098noreply@blogger.com8tag:blogger.com,1999:blog-3936311651117457138.post-1461444031138290322013-07-13T07:13:00.000-07:002013-07-13T07:13:00.567-07:00EV Celebration Day - Electric Car ShowThe car has been washed, vacuumed, and charged. I’m taking the car to Portland’s Pioneer Courthouse Square to be displayed at <a href="http://www.oeva.org/events/awareness2013/" target="_blank">EV Celebration Day</a>. I hope to show that there are solutions for reducing our dependence on oil, and that it can be fun at the same time. <br /><br />Here is my frequently asked questions list that I’ve compiled from showing off the car during the brief time since car has been on the road: <br /><br /><h3>
FAQ </h3>
<b>1. Why did you convert a car to electric drive? </b><br /><br /> I drove an electric truck 15 years ago. It was owned by my college, and I got to drive it for a summer job I held on the campus grounds crew. When I found out that I could acquire the parts needed to build my own, I knew I would someday convert a car. The simplicity, silence, and power of an electric motor is appealing. With the advances made in lithium ion battery technology, electric vehicles are feasibly alternatives to internal combustion vehicles. When the price of batteries come down, EVs sales will take off. <br /><br /><b>2. What about the production EVs that are available? </b><br /> There are a lot of nice production EVs that have recently become available, and they are very nice cars. There are a lot of electric cars currently in product development, and we should continue to see a steady increase in the types of electric cars that are commercially available This project was about picking a car I really liked, and seeing what I could do in my garage. <br /><b><br />3. Are EVs better for the environment? </b><br /><br /> That’s a difficult question and there are a lot of opinions. If your electricity is sourced from coal, the environmental impact may be about the same as a gasoline car. But if your electricity comes from renewable sources, an EV is a much cleaner mode of transportation. With an electric vehicle, I have the option to produce my own, domestic, renewable power with a photovoltaic system. This is not possible with gasoline. <br /><br /><b>4. How far can you drive on a charge, and how long does it take to recharge, and what is the lifetime on the batteries? </b><br /><br /> The car has a range of 100 miles per charge. It takes about 10 seconds to recharge (I plug the car in and when I come back the battery is charged). The batteries are capable of recharging in about 20 minutes, if you have a powerful enough charger and electrical service. My car recharges in about 6 hours after my 25 mile daily commute. The lithium batteries have a rated lifetime of 3,000 charge cycles – about 300,000 miles. <br /><br /><b>5. How much does it cost to charge and what is the payback for conversion? </b><br /> I pay the equivalent of $0.83 per gallon to fuel my car. My car would look very different if payback was a primary goal of the project. If I reach 250,000 miles, and gas process stay around $4 per gallon, I will cover the cost of the conversion. <br /><br /><b>6. How much does did it cost? </b><br /><br /> A common price for a conversion is $18,000to $22,000. I spent a little more than that getting a larger battery pack (over 40% of my total budget) and more powerful controller. I wanted to beat the stock acceleration performance of the car. <br /><b><br />7. What’s the biggest difference now that the car is electric? </b><br /><br /> The power band of the motor is available anytime I press the accelerator petal. The acceleration at any speed immediately pushes you back into the seat. With the gas engine, peak power occurs at high engine revs. It never gets old pulling up to a stop, and hearing silence from the car. Not buying gas is nice, too.<br />Joeyhttp://www.blogger.com/profile/01042435434585986098noreply@blogger.com4tag:blogger.com,1999:blog-3936311651117457138.post-54292062039728142642013-07-09T13:11:00.000-07:002013-07-10T09:17:18.659-07:00Battery ChargerThe battery charger takes AC power from the wall, converts it to DC, regulates the voltage and current into the battery pack, and stops charging when the battery is full.<br />
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<span style="font-family: Calibri;"></span>Wheeling the charger over to the car, making the electrical connections to the battery and AC power, setting up a cooling fan, and tearing the whole arrangement down each morning was getting old. Actually it was a small price to pay for the privilege of driving an electric car, but it was time to get the charger installed into the car. I welding some metal tabs to my battery rack, and bolted the charger with rubber mounts. Now, charging the car is as simple as plugging the charge cord into an electrical outlet. </div>
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I ended up getting a deal on an Elcon 1500 watt charger. The charger may be considered a little under powered for the 34.5 kWhr pack. It will take 23 hours for the 1500 watt charger to charge a fully depleted battery pack. But on average I only drive 25 miles and a 6 hour recharge is perfectly acceptable. If I find the long recharge time to be a problem, I can buy a more expensive and powerful charger.<br />
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Overall, the charger seems to be well built. The charger runs a bit hotter than I’d like, so I mounted a cooling fan to dissipate heat on the heat sink cooling fins. The charger has a logical output signal that I used to turn the cooling fan on whenever AC power is connected to the charger. This circuit is used to drive the fan.<br />
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The only other minor issue I have with the charger is lack of ease in configuration. To change the charge profile, the charger has to be mailed to the Elcon service shop to be reprogrammed for a nominal fee plus shipping charges.<br />
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The fan I found at the local surplus electronics store has build in LED illumination.
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<br />Joeyhttp://www.blogger.com/profile/01042435434585986098noreply@blogger.com0tag:blogger.com,1999:blog-3936311651117457138.post-85885971261814288162013-06-25T01:07:00.001-07:002013-06-25T01:07:08.520-07:00Rear SuspensionThe rear suspension was riding about 0.75 inches (19 mm) below stock, which implies the back end is 200 lbs over stock. To restore the ride height, and upgrade to a stiffer suspension, I replaced the 24 mm diameter torsion bars with 29 mm bars. This doubles the spring rate of the rear suspension to 250 pounds per inch of travel.
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To replace the torsion bars, I followed the <a href="http://www.pelicanparts.com/techarticles/101_Projects_Porsche_911/64-Torsion_Bars/64-Torsion_Bars.htm">procedure on the Pelican Parts website</a>. <br /><br />The car has to be jacked up, and the rear wheels removed. The lower mount of the shock has to be removed in order to allow the suspension to completely lower removing all preload in the torsion bar.<br />
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<br /> The radius arm is removed, exposing the torsion bar seated in the torsion tube.
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<br />The rocker panel trim and the round cover in the lower corner of the wheel arch had to be removed so that the torsion bar could be removed.
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The new bar is installed and the radius arm is installed.<br />
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With the extra mass and stiffer torsion bar setting the correct ride height can be tricky. When the car is in the air and there is no force on the suspension, the wheel height settles at a certain position. And when the car is lowered down, the car will compress the shocks and load the torsion bar. With extra mass, the car will settle at a lower position. With stiffer torsion bars, the car ride height will be higher. By changing the no load, angle of the radius arm, the loaded position (ride height) can be adjusted. The radius arm has a coarse and fine adjustment. For coarse adjustment, you rotate slip the radius arm onto the splines of the torsion bar in a different angles. You are limited to discrete rotational positions based on the pitch of the splines on the torsion bar. The inner rod and outer rods have different spline counts. The inner end of the rod has 40 splines for a pitch of 9 degrees, and the outer spline has 44 teeth for a pitch of 8.2 degrees. By changing the inner rod by one tooth in one direction and the outer rod by one tooth in the other direction, the rotational position of the radius arm can be adjusted in increments of 0.8 degrees, or about a ¼ inch (6 mm). I think that is a simple but clever bit of engineering. For finer adjustment, the two bolts on the spring plate of the radius arm used. The adjustment bolt has an off center collar, and by twisting the bolt, the spring plate moves up or down relative to the radius arm. <br />
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Similar bolts with off center collars are used to adjust wheel camber and toe. I don’t want to mess with these adjustments. Be returning the ride height back to the stock position, my wheel alignment should still be fine. Unfortunately, these bolts must be removed in order to access the torsion bar, so with a paint pen I carefully marked an arrow indicating position, so that the alignment can preserved when everything is put back together. It took a couple adjustment iterations to get the ride height correct.<br /><br />The main goal was to get the ride height back to stock, to prevent tire rub due to the added mass of the conversion. As long as the work was being done, I decided to upgrade to even stiffer spring rate to improve handling. The ride is firm, but not harsh. The roll in cornering was never bad, but now there is even less. There was a slow rolling feel to the car coming out of turns or going over rolling hills after the conversion. All of these issues are solved and I am quite pleased with the results.Joeyhttp://www.blogger.com/profile/01042435434585986098noreply@blogger.com0tag:blogger.com,1999:blog-3936311651117457138.post-33227873425039866872013-06-21T02:10:00.003-07:002013-06-22T16:29:31.847-07:00Front SuspensionThe ride height with the extra weight of the battery pack is lower than factory specification by 1.125 inches. I was surprised that an extra 250 lbs in the front could have such an effect, but a little research showed that the spring rate of the front suspension is 110 pounds per inch. So, the one inch drop is perfectly explained when the extra weight in the front is distributed across the two front wheels. This ride position is unacceptable because the tires are rubbing against the fenders on mildly rough road conditions.<br />
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A common racing setup to increase the suspension stiffness is to add coil springs around the housing of the shock or strut. These coilovers are great because they are easily adjustable, but this option is not cheap. In fact it is quite expensive. But they do look nice: <br />
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I chose a more economical option. The stock springs on the 911 are not leaf springs or coil springs, but torsion springs. A torsion spring is a bar, gripped at both ends with splines, that is loaded by twisting as the wheels move up and down. The torsion bars are mounted inside the tube of the A arm (see the red arrows in the image below). The spring rate can be increased by using a torsion bar with a larger diameter, and because increasing suspension stiffness is such a popular upgrade, torsion bars are available in various diameters in 1 mm increments. <br />
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The stock torsion bars are 19 mm in diameter in front and 24 mm in back. A commonly recommended setup for autocross racing and street use is a 21/28 mm torsion bars. I did some calculations, to take into account the extra mass of my batteries, and determined that the 22/29 mm bars would be good in my car: <br />
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The old bars are slightly bent. <br />
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<span style="font-family: Calibri;"> </span>Installation wasn’t too bad. It took me about four hours, following the <span style="font-family: Calibri;"><a href="http://www.pelicanparts.com/techarticles/101_Projects_Porsche_911/64-Torsion_Bars/64-Torsion_Bars.htm" target="_blank">procedure on the Pelican Parts website</a>.</span><br />
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With the ride height restored to factory specification, I took the car out for a test drive, and I must say the difference is astounding. The biggest issue was tire rub, and the new springs completely solved that problem. But surprisingly, the steering was much lighter, and more like I remember from when the car was still gasoline powered. I think the alignment and steering geometry must have been compromised with the lower position. Further, I can feel that the back end of the car moves around more than the front. There is a rolling feel or slow bounce that is distinctly occurring in the back of the car coming out of turns or cresting rolling hills. I can’t wait to see how the car handles when I get the new rear springs installed.</div>
Joeyhttp://www.blogger.com/profile/01042435434585986098noreply@blogger.com0tag:blogger.com,1999:blog-3936311651117457138.post-29242345054524151262013-06-17T00:08:00.003-07:002013-06-17T00:08:34.590-07:00Brake Booster Pump InstallationThe first EV component I purchased was a vacuum brake pump kit (<a href="http://eporsche911.blogspot.com/2012/02/brakes.html" target="_blank">see Brake Kit</a>). For a year and a half that kit has been sitting in a large, but as of late, dwindling stack of parts awaiting installation. After driving around for a couple weeks with no brake booster assist (essentially manual brakes), I decided to install the brake pump. The brakes stopped the car just fine, as I have been limiting my top speed to 45 MPH until the motor brushes are seated. But, if ever a situation demanding a quick stop should arise, I would want the brake booster active.<br />
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Here is the block diagram of the brake vacuum system.<br />
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The most difficult part of the installation is finding the location where everything fits in the available space. The vacuum pump and reservoir are in front of the batteries, near the front bumper.<br />
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The relays are mounted next to the 12 volt battery.<br />
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This is the fitting that connects to the brake booster at the master cylinder. The size is 12 mm and the vacuum kit is 3/8 inch. I was able to use some of the existing metric vacuum hose and attach it to a 1/2 inch to 3/8 inch reducing barbed hose coupler.</div>
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The vacuum kit didn't come with enough vacuum hose for my installation, and at the pressure switch you can see that I switched to a blue vacuum hose.</div>
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The pump makes a small whirling or hum sound for a second or two as it pulls a vacuum. The pump turns on after every 2 or 3 presses of the brake pedal. Above 15 MPH, road noise drowns out the sound of the pump and I can’t hear the pump at all. I understand that VBS now makes a piston pump that draws less power, and is even quieter.Joeyhttp://www.blogger.com/profile/01042435434585986098noreply@blogger.com0tag:blogger.com,1999:blog-3936311651117457138.post-82407296309493822102013-06-16T23:15:00.000-07:002013-06-17T13:17:47.265-07:0012 Volt Power SourceThe reason most cars have a large 12 volt battery is because it takes a lot of amps to start an internal combustion engine. Now that the engine has been removed, the next largest load in the system is headlights at just under 200 watts. With every system turned on I measured 600 watts of power draw. The size of the 12 volt battery can be greatly reduced. <br />
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Instead of an alternator to charge the 12 volt battery, there is a DC-to-DC converter which takes the 192 volts DC from the main traction pack, and steps the voltage down to 13.2 volts (exact voltage is configurable and depends on the type of 12 volt battery used). At a minimum, the DC-to-DC converter should be sized to handle the average 12 volt load of the car. During peak power draw, the battery will automatically contribute current to handle the demand, and automatically accept current to charge back up when the DC-DC converter has spare capacity. My DC-to-DC converter has enough capacity to handle peak load, but I still wanted to install a battery for redundancy. If the DC-to-DC converter should fail, I want to have enough reserve energy to get the car safely off the road with functional headlights and hazard lights. I’m using a 18 AHr sealed lead acid battery (this is the same type of battery used in computer power backup systems or UPS) and this is enough to run the 12 volt system solo for 20 minutes. <br />
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I made up some aluminum brackets to mount the auxiliary battery and DC-to-DC converter. <br />
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I also picked up a metal project box at an electronics surplus store and mounted a fuse and filter network to condition the 192 volts going into the DC-to-DC converter. It is reported that voltage ripple from the controller, switching up to 1000 amps on acceleration, can kill the input stage of the DC-to-DC converter. A diode and inductor in series on the input protects the system. The diode is mounted on a heat sink. It is probably overkill, but for an extra $1 USD at the surplus store, I figured why not. <br />
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Joeyhttp://www.blogger.com/profile/01042435434585986098noreply@blogger.com0tag:blogger.com,1999:blog-3936311651117457138.post-29045843809186170222013-06-12T00:44:00.002-07:002013-06-12T00:44:51.985-07:00Porsche with a CordNow that the car is drivable, I need to finish the charging system. The charge plug is something I’ve been thinking about from the very beginning. I decided to install the charging port behind the door of the gas filler tube. The car will still be refueled from the same physical location, but the flow of hydrocarbon molecules is replaced with electrons. The plug is a NEMA L6-30P, a twist lock connection rated for 250 volts and 30 amps. The filler on the left (with plastic cap) is for windshield washer fluid.<br />
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Joeyhttp://www.blogger.com/profile/01042435434585986098noreply@blogger.com2tag:blogger.com,1999:blog-3936311651117457138.post-57798448362321234112013-06-06T17:37:00.002-07:002013-06-12T11:14:47.017-07:00Impressions of the First Drive<div class="MsoNormal" style="margin: 0in 0in 10pt;">
<span style="font-family: Calibri;">After the last battery cell was connected and the controller was programmed, I could barely contain my excitement as I lowered the car from the four jack stands where the car has been perched for the last year.<span style="mso-spacerun: yes;"> </span>My dad was visiting from out of town and I was proud to show him firsthand the project I’ve been talking about for more than a decade.<span style="mso-spacerun: yes;"> </span>I backed out of the driveway with anticipation.<span style="mso-spacerun: yes;"> </span>The first thing I noticed was the 8 kHz hum of the controller.<span style="mso-spacerun: yes;"> </span>The squeal is audible in my <a href="http://eporsche911.blogspot.com/2013/06/video-first-test-drive.html" target="_blank">video of the first drive</a> and quickly becomes fatiguing.<span style="mso-spacerun: yes;"> </span>I put the transmission into 1<sup>st</sup> gear and pressed the accelerator and the car moved forward.<span style="mso-spacerun: yes;"> </span>The response to the throttle was rather weak, but with the controller set to limit the motor to 100 Volts and 400 amps, there was only 53 horsepower on tap, a mere 25% of what will be available when the motor limits are increased to 170 volts and 1000 amps. The motor brushes need a chance to seat properly before handling more power.<span style="mso-spacerun: yes;"> </span>But I was moving under electric power and the vibration free propulsion of the electric motor was fantastic.<span style="mso-spacerun: yes;"> </span>The clutch worked, the transmission was fine, there was no smoke from the batteries, even the homemade tachometer was driving the stock gauge in the dash, and a sense of relief that there were no major problems was replaced with satisfied pride that the car was finally in motion.<span style="mso-spacerun: yes;"> </span>A dream was finally becoming reality.</span></div>
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<span style="font-family: Calibri;">In the front, the car is sitting about an inch lower with the extra weight of the batteries.<span style="mso-spacerun: yes;"> </span>The tires rub the fenders when I go over any bumps in the road.<span style="mso-spacerun: yes;"> </span>The solution will be to install stiffer torsion springs in the suspension.</span></div>
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<span style="font-family: Calibri;">The controller has a quiet mode that uses a higher frequency to pulse power to the motor.<span style="mso-spacerun: yes;"> </span>Luckily quiet mode is appropriately named, and now the hum of the controller is not detectable.</span></div>
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<span style="font-family: Calibri;">I noticed that after a few short drives that the motor gets hot – about 130 degrees F (55 deg C).<span style="mso-spacerun: yes;"> </span>I think this could be a reliability issue over time, so I will be ordering a blower to force air through the motor and reduce the temperature rise.<span style="mso-spacerun: yes;"> </span></span></div>
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<span style="font-family: Calibri;">There is still a lot to be done to finish the car, but driving the car for the first time under electric power is a huge thrill and motivator to keep going.</span></div>
Joeyhttp://www.blogger.com/profile/01042435434585986098noreply@blogger.com5tag:blogger.com,1999:blog-3936311651117457138.post-48727065008628706222013-06-02T10:43:00.001-07:002013-06-02T10:43:41.148-07:00Video: First Test Drive<div class="separator" style="clear: both; text-align: left;">
The video for my first electric test drive:</div>
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<iframe allowfullscreen='allowfullscreen' webkitallowfullscreen='webkitallowfullscreen' mozallowfullscreen='mozallowfullscreen' width='320' height='266' src='https://www.youtube.com/embed/vu4m3TK5Wx0?feature=player_embedded' frameborder='0'></iframe></div>
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My dad was in town and helped with the last two days of wiring, so he got the first ride. </div>
Joeyhttp://www.blogger.com/profile/01042435434585986098noreply@blogger.com6