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1986 MR2 EV Conversion Notes Ken Chiang. The main components ICE Components removedReplaced by: Radiator system ----->n/a Engine---------->motor Fuel.

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Presentation on theme: "1986 MR2 EV Conversion Notes Ken Chiang. The main components ICE Components removedReplaced by: Radiator system ----->n/a Engine---------->motor Fuel."— Presentation transcript:

1 1986 MR2 EV Conversion Notes Ken Chiang

2 The main components ICE Components removedReplaced by: Radiator system ----->n/a Engine >motor Fuel Tank >batteries & charger Alternator > DC/DC converter Starter > n/a ECU > controller **The hardest part was figuring out how to fit the battery racks in the small space

3 Major costs 180AH 144V LiFePO $11,000 Motor $1550 Controller $1500 Charger* … $2500 Cables,contactors,DC-DC,instrumentation...$1000 Adapter plate $825 Aluminum racks (materials & welding) $800 Misc Tools $500 New suspension/wheel bearings $1000 Other … $5000

4 How much time? Elapsed time: 3years July'08 – July'11 Actual time: 1 year? Baby boy! Working after work No mechanical background

5 Project Resources (1) Internet! Evalbum.com: met Steve McDonald Electric-cars-are-for-girls.com Electric Auto Association! Books: Haynes Manual for 1986 MR2 Convert it: Mike Brown Build your own electric vehical: Bob Brandt

6 Project Resources (2) Friends that I've met after I started: Steve McDonald: 1987 Honda Civic (lead acid) Honn Chhim: 1987 Honda Civic (LiFePO4) Michael Brooks: 1990 Honda CRX (lead acid) Kevin Philips: Aluminum Welder (owns fab shop in Hayward- great work and very reasonable rates)

7 Project Resources (2) Friends that I've met after I started: Steve McDonald: 1987 Honda Civic (lead acid) Honn Chhim: 1987 Honda Civic (LiFePO4) Michael Brooks: 1990 Honda CRX (lead acid) Kevin Philips: Aluminum Welder (owns fab shop in Hayward- great work and very reasonable rates)

8 Project Resources (3) Suppliers that I've used EV america in NH: sells kits, offers clutchless design KTA services: adapter plate for a clutch system. Manzanita Micro: nice PFC Battery charger and LiFePO4 distributor CleanAutoLLC: EV display 2 (highly recommended) Alco Metal: cheaper AL than Home depot Naylor steel: anything steel PickNPull: salvage yard for finding misc car parts.

9 Good Decisions LiFePO4 vs. wet lead acids Longer range Cheaper per year Better performance Less maintenance and mess Aluminum racks Saved 150 lbs Coulomb counting fuel gauge vs. voltage based EV display 2 has a lot of useful features and accurately tells me how much fuel left.

10 What would I do differently? Convert a 4 seater New baby boy! Can't fit my family in my MR2. :( Start with something with a better body and power doors and locks instead of adding on afterwards.

11 Other learnings Pay special attention to the bolts on the drive train! CV joint coming lose can cause a lot of damage! Check NEMA connectors monthly!

12 Learnings (cont...) Design system within specs of each component: LiFePO4 rated at 4C 4*180=720amp draw max ADC 8 motor is rated up to 120V, don't run 144V! LiFePO4 must be banded to prevent expansion during charge and discharge cycles LiFePO4 should not be oriented flat with terminal on side (per manufacturer) Can't get white carpool sticker anymore? (tried 3 times) Manzanita PFC chargers not isolated, don't touch terminal while charging!

13 Loving the Drive! Almost 8,000 miles == $1k savings in gas Solar panel payback: 22 years to 8 years. Places that I've been in my EV from my home in CV SFO 54 miles Livemore 48 miles San Jose 66 miles San Rafael 76 miles (charged at parking garage) Planning farther trips by utilizing J1772 adapter for public charging for free! (until 2013)

14 Maintenance Checklist Check Tire pressure Monthly Check high current connectionsMonthly Measure top/low voltagesMonthly Check NEMA connectorsMonthly Check all bolts (racks/cv shaft,etc)every 6 months Rotate Tiresevery 6 months Check Brakesevery 6 months Top off transmission fluid?every 6 months Check motor brushesevery 1 year

15 Feel free to contact me! Ken Chiang kchiangusa at gmail dot com


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