Presentation on theme: "“CO 2 LES” Converting A Gas Powered Corolla Wagon into an Electric Family Hauler By Sten Mander."— Presentation transcript:
“CO 2 LES” Converting A Gas Powered Corolla Wagon into an Electric Family Hauler By Sten Mander
Overview Part 1: The car selection process Part 2:Removing the gasoline components Part 3:Power to manual steering conversion Part 4:Installing the motor Part 5: Rear batteries and charger Part 6:Instrumentation Part 7:Brakes and suspension
I need a light car that is large enough to take two kids in car seats to school… Part 1: The Car Selection Process
I chose a 1991 Toyota Corolla station wagon with a good body and a clean interior.
Then I installed a tow bar so I could tow the car home after the engine was removed.
I have driven the car about 500 miles. The odometer is now at 195,000.
Next, the engine and all the gasoline parts needed to go.
This is the MES vacuum pump for the brake booster. The car weighs 3200 pounds and really needs power brakes!
This is the current engine compartment. Eventually, the wiring will be covered with black flexible loom. Vacuum pump for the brake booster
The Spring-Works in Santa Rosa made the 900 pound over weight springs for the rear of the car.
Ernesto at Bosh Automotive is removing the stock springs with a spring compressor.
Compare the new spring (top) to the stock spring (bottom).
The new spring fitted in the rear of the car at Bosh Automotive.
My son Erik and the Corolla with the new springs installed before the 660 pounds of batteries and the 100 pound battery rack and platform were installed.
The top of the rear wheel arch was 28 inches high!
Erik Mander and the Corolla with the new springs and the batteries installed. The top of the rear wheel arch is now 25 inches from the ground, down 3 whole inches!
For every 14 miles I drive the electric car, I save $3.00 in gas compared to driving my truck.
Design and Build Team Members 1.Tow Bar: Road Master, Or 2.Engine Removal:Casa Grande Auto Tech, Ca 3.Brake Vacuum Pump & Heater: Metric Mind, Or 4.Original Conversion kit:Wilderness Electric Vehicles, Ut 5.Manual Steering Rack:Truck world USA, Ca 6.Adapter Plate Modifications:John Balen, Ca 7.Machine Work:JRL Machine, Ca 8.Galvanized Battery Racks:Beauchamp Welding, Ca 9.Undercoating:Rhino Lining 10.Star board and Charging Outlet:Fred Fritz Electronics, Ca 11.Batteries and Welding cable:Battery Systems, Ca
More Team Members 12.Custom Rear Springs:Spring-works, Ca 13.Spring Installation:Bosh Automotive, Ca 14.Transmission Rebuild:Trans-man, Ca 15.Motor and Controller upgrade:Electric Vehicles of America, NH 16.State of Charge Gage :KTA Services, Ca 17.Safety Concepts :Chris Jones, Ca 18.Heinemann Safety Breaker:EV Parts, Wa 19.Instrumentation:Westberg Manufacturing, Ca 20.Final Assembly Inspection:Tony Travis, Ship Shape Marine, Ca 21.Strong Helpful People:John Shribbs, Todd Creighton, Ca 22.Other Conversions:www.evalbum.com