wish list

In general, I'm very pleased with it, though it has some limitations.

pluses:

1) If I plan my trip, I can get to wherever I usually go in Eastlake, and back home again.
2) It's cheap to drive...about a tenth of what it costs to drive that old POS Jeep.
3) It's quiet.
4) It looks cool.
5) It carries the family, too, with groceries.

minuses:

1) limited range (11 miles).  No way I'm making it to old Chula Vista on a single charge.
2) Recharge time...about an hour for every mile driven.
3) slow.  45 mph on a flat.  25 mph climbing a steep hill.
4) batteries need lots of minding and maintenance.  Acid will dribble and destroy shit.
5) I'm having to replace the old parts, i.e. wheel-bearings, shocks, etc.  Not a problem, really.


What's left to do with the Eggplant:

new front shocks
new rear bearings



Projects in mind for the future:

120 volt setup with a fiberglass kit car i.e. Bradley.

Electric motorcycle!

Some data

Range: 11 miles

Beefing it up

On inspection, I see where battery acid has dribbled down onto my battery frame.  This can happen for a couple of reasons:
1) sloshing around while driving (bumps, corners, drag racing, etc)
2) overcharging.

So, today, Christmas Eve, a bright, sunny day, I yanked out all my batteries, cleaned the corrosion off my steel battery rack, painted it with rustoleum and rubberizer, and reinstalled everything.

I fixed some of the always-present shock-hazards by placing split plastic tubing over all the battery terminals.  Maybe I won't get the shit shocked out of me so often....

One thing I noticed....I still have 4 amps running through the motor even when the 72V circuit is open and the key is off, but only when the charger is on.  I can't figure that one out.  When the charger is unplugged and the circuit is open, no current.

Hmmm...I'll have to meditate on that one for awhile.  I'm not sure if its a problem or not.

Merry Christmas, all my dedicated fans.

Every watt counts, when you live on a hill!

From driving this thing around on short hops every day, I am learning a completely new way to drive.  I guess it's "mindful driving".

I let gravity do the work, whenever I can.  When I'm climbing the hill, I try to keep the amps down under 200.  I COULD floor the throttle, which makes the motor draw over 300 amps, but it only goes marginally faster, and it drains my batteries FAST.  Also, I can power-climb most of the way up the hill, and let my momentum carry me up the rest of the way, and coast down the other side!

I am intensely aware of the knap of the earth, knowing that when my power is gone, I'll have to be dragged home on a rope.  Not gonna let that happen often!

Traffic lights....every time I have to hit the brakes, I'm converting some of my hard-won forward momentum into wasted heat.  I try to time it so that I don't have to stop before the light turns green.  Start-up from a dead stop is a big drain on the batteries, too!  Newton was a pretty insightful guy!

I imagine these methods would save a lot of gas in a traditional vehicle, too.

http://www.facebook.com/photo.php?fbid=2406284644712&set=a.1884858089374.2096212.1479043756&type=1&theater

back of the envelope

6 A x 75 V = 450 W

6 hr recharge = 2.7 kWh , went 8 miles

I pay $0.10 / kWh,

$0.27 for the trip, or 3.4 cents per mile.


(NOW...compare to my V8 engine....)

13 miles per gallon petrol

$3.75 per gallon petrol

29 cents per mile.


It looks like I'm getting 8.5 times the bang for my buck!

This is working GREAT!

Yesterday, I did a full brake job (new pads/shoes, flushed the old fluid out and put new in).  I re-packed the rear bearings with grease, since I was at it.   I figures, since I made it go, I'd better be able to make it stop!  Nicolas helped me bleed the lines this morning.

This morning, we went down for haircuts, and to blockbuster to drop off the movies, and back home.  8 miles even, and down to 90% SOC! 

AWESOME!  I'm trusting this thing more and more.  I will gradually go further distances, to see exactly how much local range I get.  If I can make it to Walmart and back without going lower than 60% SOC, I'll dance a little jig, film it, and post it here!!!!

Day 2

Overnight charge, pack voltage read 80 volts (Full!)

It's a bit murky inside....my dashboard leaks and lots of rainwater came in yesterday while playing.  I think I probably toasted my radio...we'll see if it dries out.

I took it to school today, pack voltage reads over 76 V.  I'm halfway home!  I think it will make it back up the hill OK.  I'll call Dave for a drag if I need it, but, FINGERS CROSSED!

I made a scouting pass around SWC yesterday...seems there is NOWHERE I can park close enough to an electrical outlet!  Bummer!  So today will be telling...Can I make it to school and back home on a single charge?

We shall discover!

(later)

I MADE IT!   Whoohooooo!  

Big possum-eatin' grin!

Full charge, Day 1

I charged the battery pack overnight, and the pack voltage read just under 80V.  I gotta watch out for overcharging...that will shorten my batteries (batteries are PICKY, it seems!)

I dropped the kids off at school, went for coffee, went BACK to school, and then BACK for coffee, and came home. (says something about my habits....).  Up and down hills.

I checked the pack voltage again before plugging her back in....4.9 miles and 75.5 volts, which is still over 90% SOC.  Things are looking better!

Brother Bump is coming over later to play...I'll grab some video to post.

Big Dave and I went down the hill and back, another 4.5 miles, after 1.5 hours of charging.  SOC is down to 80%.  Dave took it around the cul-de-sac and around the block, and we plugged her back in.

Hear the ROAR!

                                 

THE ELECTRIC EGGPLANT LIVES!

Maiden voyage to Starbucks!

The fuse came today.   I wired it in (correctly, this time), and checked for alignment of the motor while it was still on jackstands.  Took it down the hill for coffee, and back up the hill. (1.6 miles).  Hills are tough....I took the family for a joyride around the neighborhood, and down a big hill.  Coming back up the steep hill was slow, and sucked a lot of juice.

On the same charge (SOC read 76V), I decided to take it to SWC, 2.5 miles away.  Downhill is NO problem (gravity, y'know?).  Coming back up hill, I ran out of juice.  Odometer read approx 9 miles elapsed when it died.  I got a pull home (10.8 miles for the day).

Now, I probably didn't have a full charge in the pack when I started today.  I've read that conditioned batteries and worn-in motor brushes will improve efficiency and range.  I will also look for a place at school where I can park near a power outlet, and surreptitiously charge while I'm at work (shhh...don't tell!)

I think this will work as a commuter vehicle...these are growing pains. (I hope!)

It lives, though!  The wheels turn.  It rolls by electric.

Where's my fuggin' fuse!?!?!

I ordered it, paid for it to be shipped express/rush/overnight/want it NOW, on Monday morning.

This thing got toasted.  Coulda had a weinie-roast!

It's Friday, and I still don't have my damned part!  It's not like I can just wander into Walmart or Radio Shack and pick up a 400 amp fuse!  I NEED this thing before I can roll-out!

sigh.  Patience.

A Mulligan.

The lessons from yesterday were learned well; my wounded pride at switching polarity notwithstanding.

I beefed up the motormount bar so that it wouldn't buckle if things bounced around some.  That motor is dense!, and it's positioned in the middle of a 3-foot length of angle iron.  Leverage is powerful stuff.

I installed a battery isolator that I can access from the front seat, so I don't have to depend entirely on the 12V contactor if things go wrong at the high end.

Nice to have a kill-switch handy!

I put in a set of airhorns and mounted the chargers under the front bonnet.  Lots of cargo space up there for groceries and misbehaving children.

Plugs into house current.

I cleaned up the mess from the fire extinguisher and made sure things were in their proper polarities, and admired my nearly-empty engine compartment!


LOOK MA!  NO ENGINE!



When the replacement 400 amp fuse gets here, this buggy will be road-worthy.  It's there.  It's ready.  I've heard often, and I tend to believe it so, that "everything happens for a reason".  Perhaps yesterday's mishap was an important event, and prevented something worse later on.  Yeah...I'll look at it like that.

So much for the safety check!

Damn.  I should NOT make important electrical connections after work, when I'm tired and there's not enough light.

I had reversed polarity at the controller box.  A simple, stupid, crucial error.

I turned the key on the 12V circuit, the contactor closed the 72V circuit, and promptly welded itself closed.  The 400 amp fuse burst into flame.

Turning off the key didn't stop this horror-show, because of the stuck contactor.  I hit it with the fire extinguisher, and by then the fuse had finally vaporized. 

This tells me I ALSO need some kind of a manual disconnect, to break this circuit, in case of faeco-ventilatory intersection.


I felt for sure I had also toasted the $750. controller.  I felt like crying.  What a dumb thing to do!  "+" and "-" are IMPORTANT SYMBOLS!

After a few minutes of cussing and smoking, I calmed down long enough to call the tech guys to see how to test my controller.  It turns out I got lucky...the fuse protected it from my error.

Now I just am out another $40 for a new fuse and time waiting for it to ship out.

I did make a mount to keep the motor from jumping around, so the day isn't completely shot to hell.

Longer is not Better!

I knew the Devil would be in the details!

I ran into the same hitch as some previous attempts I read about, with the same kit from this outfit...

When I tried to slide on the coupler to the transaxle, it's 1/2" too long! (Or the adapter plate is 1/2" too short).
The other blogger solved this by having a spacer plate machined ($80, and he was surprised!), because he didn't want to "damage the transaxle in case he ever wanted to sell it".

Well SCREW that!  I'm hacking 1/2" off the darned transaxle spline tomorrow.  I'll MAKE it fit!

(brought to you by the Bigger-Hammer School of Engineering)

Motor has arrived!

All the parts are here.

All the cables are cut to length, and terminated.

Tomorrow after class, it all gets assembled.

To do:

1) mount motor to adapter plate, key shaft.

2) mount this to transaxle spline, bolt in place

3) connect control cables to motor.

4)  attach controller box somewhere

5)  see about stabilizing motor to existing motor mount brackets...may need to fabricate this out of angle iron

6) SAFETY CHECK...connections, potential shorts, grounding, etc.

Why, that would just suck!

Sheeeyit...if all goes well, this thing should be rolling under its own power by sundown tomorrow!

ALMOST READY!

The first shipment of parts arrived yesterday.  Two steady days of work, and I have made satisfying progress.

1) 12V keyed circuit closes high voltage circuit when key turns on.
2) 72V circuit all wired and ready for the motor.
3) Chargers all wired in to the 12V and 72V system.  (Style points for the extension cord coming from the gas port!)
4) Throttle box mounted and ready for controller box.

Hands are cut, scraped, burned, pinched. At least they match.

Lesson of the Day...there is one cubic FUCKLOAD of power in 6 car batteries wired in series, and a capacitive charger!  I electroplated my hand with my wirecutters when a jet of molten copper and steel erupted from them as I cut through both charger-wires to the 72V system. (Dumbass!)  Sounded like a gunshot, too!

Have healthy respect for amperage!

Left to do:

mount motor and controller box (waiting for it!)
fix rt-turn lens, front
see about why backup lights arent working.

Some BLING

Battery access

The motor kit is on the way.  In preparation, I figured I needed to have easy access to the battery pack.  There is room for 5 of the 7 batteries on the rear deck above the engine cavity, but they have to be forward of the access hatch (hence, they are inaccessible for maintenance).  I need to be able to drag the batteries back, over the engine hatch, when needed.

hatch open, batteries in their slots

60 lbs X 5 = 300 lbs (right? Hell, idunno...I'm a biologist, not a fuggin' mathematician!  I can't even SPELL "mathematician" by myself!).

300 lbs of lead-acid batteries all connected to each other with heavy gauge cables.

And I don't want the engine hatch to support that weight when I'm futzing around with the battery pack trying to shock myself or start fires.

fancy rail system

"TAA-DAHHH!!"

I rigged up a rail system with 1/2" angle iron, so that my newly constructed steel battery box (also angle-iron) can slide fairly easily fore-and-aft, as needed.  I still want to secure the 2 rails to the sheet metal of the back-deck a little better, but it works great!  A little grease on the track, and it's like butta!  I'm GUESSING that I won't be starting off with so much torque that the pack slides backwards while I'm driving...if it does, I'll deal with it later.



The other two batteries nestle nicely under the back seat.  No worries.

Just ordered the kit.

Wrote a check today for $3125.00.  (Here's the kit)  Supplier says 3 - 6 weeks for everything to be delivered.

The car is ready to roll...just need to install the powerplant!

Keep your fingers crossed for me.... Maybe rolling by Christmas?


(Anyone want to buy a 1998 Jeep Cherokee?  $3125, and it's YOURS!  Runs great!)

no comment, except...

It costed $116.00 to transfer title and registration.  (Done)

Oh, and by the way....YES, I'm keeping the eggplant-purple color, even though I'm catching a lot of bullshit about it!  I can't very well call it "The Electric Eggplant" if it's not eggplant-purple, now can I?

And if I paint it candy-apple red, I'm sort of making a promise that I won't be able to keep (remember...I don't expect a top speed of much over 40 mph!)

ANYway, that's all beside the point.  I'll get the damned thing running before I make it look pretty.  Ease up!

Doug's Idea....

Given that there is no engine...

and, there's a big hole that Dad cut in the floorboard,











We could save a lot of money by not bothering with a motor and just having a "Flintstone-mobile"!

(Dad later replaced the rotten floorboard with fresh 20-gauge sheet-metal, riveted in place.)

Evaluation

The Eggplant has found a home.  Dave A.'s truck, Mike A., Dave B., and Art A. came along for the entertainment.  I ALMOST missed out on the trailer...the monkey on the lot told me I didn't need a reservation, but I got the last one with only two minutes to spare!  $70 with the insurance (ALWAYS get the insurance!  I ripped the bumper off a Mercedes-Benz with a 24-foot UHaul truck once...SO glad I bought the insurance!)  Got the car home from Santee, no problems.  I spent a while giving it a once over.  I drained the fuel from the tank and ripped out all the fuel-supply stuff.  I found a rotten place in the floorboards, but I can patch it.  The kids had a blast crawling around inside.  Nico helped me with the fuel tank connections.  (My eight-year-old motorhead!).

SCORE!

When I was digging around in the front hood and taking the spare out, I found a bonus!  Gen-yoo-wine Save-On brand Vodka in a plastic bottle!  The Universe seems to be unfolding nicely.

I'll spend some time patching up the rusty spots, while I try to save the cash for the motor kit.  I found space for 5 of the batteries in the engine upper-deck, and room for two under the rear passenger seat.  If I DO go with the 120-volt kit, I have room for more batteries up front.  I will most likely go with the 72-volt kit for the prototype.

I need corporate sponsorship!  Any ideas?

Pick-up day

Piece of shit. Don't need it.

Unfortunately, I didn't get the opportunity to weigh the thing with the engine in it, and I probably won't have a chance to weigh it without the engine, either.  I'm guessing that with my 7 X 60 lb. batteries, and the 60 lb. motor, plus all the other electric crap in this kit, the converted car may outweigh the original.  But I guess I'll never really know.  I'll have to find some truck scales around here eventually...there may be some down at the Border (hassle!) or at the SBX offices down in Otay Mesa.

Gobs of room for batteries!

I'm taking Dave Ayala's diesel truck and a UHaul trailer to go drag the thing home today.  Dave wants to provide heckling-I-mean-help in loading and unloading it.  Dave Bump wants to come along, too.  It's an adventure!  These guys are my best friends, and they need an excuse to get away from the house.

It may take some time to raise the $$$ needed for my kit, but I'm sure there's work I can do in the meantime, i.e.  rust repair, taking out gastank, figuring out battery locations, building racks, etc.


Anyway, I have to make a decision soon.  The 72-volt kit needs 6 batteries, and has a top speed (according to supplier) of around 50 mph, for about $3,000.  The 120-volt kit needs 10 batteries, can get to highway speeds, but costs $4,650!  Damn.  Do I want to spend the extra $1,600 to go a little faster?  Decisions, decisions!

Meet the Electric Eggplant

$1300, I'm buying it without the engine.

On the Hunt!

Spent the morning cruising around the auto wrecking yards in Otay Mesa.  All of the Beetles down there have been heavily molested!  I'm not looking at a total renovation job, here!  I just want a VW that rolls and has all its parts!  It seems that now it is trendy for people to scarf up vintage beetle chassis, fix them up, and sell them for $$TOP-DOLLAR$$!

Ugh.

I may have a line on a type 3 here .  Maybe I can convince him to sell it to me for less without the engine.  Stay tuned, sports fans!   (Like the purple? I kinda do!)

DAMMIT!!!

My Bradley was sold out from under me!

Oh, well.  At LEAST the guy e-mailed me to let me know...I can imagine how rip-shit-pissed-off I'd be if I drove my ass all the way up to LA to find that out!

Still looking for a platform, then...stay tuned.

October 19, 2011

Ok.  I am SICK to DEATH of blowing $80.00 a tank for petrol every week in my old POS Jeep Cherokee V-8!  I'm done with that!  Time to start practicing what I preach.  I teach biology at community college in San Diego, and I am an oceanographer trained at Woods Hole Oceanographic Institution and MIT.  I have some firm convictions about climate change, and I believe that I am partially responsible!  I want to do something about it!

I am heading up to Orange County with a UHaul trailer ($54/day) to drag home an old Bradley GT II fiberglass body on a 1973 VW Beetle framehere.  It has no engine, but who gives a shit?!  It also doesn't have a transaxle, but we'll see what I can do about THAT!  Anyway, I'm looking at around $500 for the body and maybe the transaxle.

The plan is to buy a 72 volt electric motor and controller kit from a supplier for about $3K ($2995 plus shipping!)here.  I've started buying up Marine Deep-Cycle 12V Lead-acid batteries from the local autoparts chain, about $100 per (the manager gave me a discount and a break on the core fee.  I'm grateful.).  I'll need seven:  six to drive the motor and one for accessories.  Lots of weight, but the highest energy density for the price!

My wife already knows that I will probably come home with the Bradley.  Hell...it's light!  Lighter than a VW Beetle body, even!  It's fiberglass!  AND, it has the coolness factor to it!  She would rather me buy a VW Beetle, for practical considerations...I can carry both kids in a VW.  I may not be able to carry both kids in the Bradley.  We'll see.  Anyway, she's right about one thing...I probably will come home with the Bradley instead of a Beetle.  She knows me pretty well after 20 years.