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Table of Contents
Introduction - Electric car benefits, electrical terminology, tools& parts needed
Chapter 1 - Finding a vehicle to convert
Chapter 2 - Information about DC & AC electric motors
Chapter 3 - Information about DC & AC motor controllers
Chapter 4 - Information about batteries, how to obtain them
Chapter 5 - A closer look at the various parts involved with yourelectric vehicle conversion
Chapter 6 - Getting started with your electric vehicleconversion. Includes removing wires, removing unneeded
parts, installing the motor/transmission
Chapter 7 - Further steps involved in your electric vehicleconversion. Includes installing batteries and installing othervehicle parts.
Chapter 8 - Final checks to make and steps to take, starting upyour electric car for the first time
Chapter 9 - Helpful resources
Chapter 10 – My Home-Made Renewable Solar & Wind EnergyRecommendation
Introduction
Dear Friend,
Congratulations on investing in the Electricity4Gas manual.
You are in a small group of people. Not many people areintelligent or informed enough to make such a good choice andsave themselves money and help the environment at the sametime.
You will soon be on your way to eliminating all gasoline costs,and reducing emissions.
The instructions and plans in this guide have worked previouslyfor others and should work for you.
If this is all new to you it may seem complicated at first. Wesuggest you take your time, and re-read the guide a couple oftimes.
You always have the option of seeking assistance from acompetent mechanic, or a mechanically minded friend, familymember or acquaintance perhaps, should you need help withsomething.
There are a number of text links (that appear in blue) throughout this guide. If you are unfamiliar with the Internet, byclicking on these links, you will be taken to a web page. Pleasemake sure you are connected to the Internet before clicking onthe links.
We have created this manual to be a no-nonsense straight-to-the-point guide. We’ve kept the manual simple so it’s easy toread, and we haven’t ‘padded’ or added ‘fluff’ just to make itappear bigger.
Enjoy!
Why should you convert your car to run on electricity?
There are many reasons to convert your car to electric, we couldtalk about it for hours, but since we’re keeping it simple here arethe three big reasons:
Environment – An electric vehicle has almost zero emissions.Current gasoline cars are big contributors to air pollution.
Cost – The cost of running your vehicle on electricity is verysmall in comparison to a vehicle that runs on gasoline. You willsave hundreds or thousands of dollars a year, when you don’thave to pay for gasoline.
Minimal maintenance – There is minimal maintenanceinvolved in running an electric vehicle. Compare that to oilleaks, engine breakdowns, exhaust system problems etc with agasoline car. You will save hundreds of dollars a year onmaintenance costs.
Electrical terminology
Below we explain some of the electrical terms used in thisguide:
Wattage (watts) - A measure of the amount of work done by acertain amount of electric current (amperage) at a certainpressure (voltage).
Volts - a type of "pressure" that drives electrical chargesthrough a circuit.
Amperage (Amps) - The rate of flow of electricity throughwire.
Kilowatt Hour - The work performed by one kilowatt ofelectric power in one hour. An example is a 100-watt light bulbthat is turned on for ten hours. The power rate would be 100 x10 = 1,000 watt-hours or 1 Kilowatt hour.
Direct Current (DC) & Alternating Current (AC) -
Direct Current is self-explanatory. Alternating Current is anelectric current that reverses direction, usually many times persecond.
The most important difference between AC and DC power isthat DC current can be stored in a battery while AC powercannot.
Common DC voltages are 12, 24 and 48.
Tools needed before you start
The first step is to have a work area. Make sure you have plentyof space to make the process as easy as possible.
There is grinding and fitting of metal involved so you shouldconsider doing that kind of work outside.
The tools you may use include:
• A hoist
• Clamps and vice grips
• Cordless drill
• Jigsaw
• Small grinder
• A socket set
• Various wrenches (both imperial and metric measurement)
• Screw drivers
• Sand paper
• Welding equipment
• Work bench
Tips on obtaining these tools:
• Look out for sales – Look out for in-store-sales where youcan buy inexpensive tools for your home workshop.
• Ask for tools as birthday & Christmas presents.
• Look for cheap tools at auctions and yard sales.
• You could rent these tools.
• You can ask some friends or family members to borrow theirtools.
Further notes on welding
At some point you will need to weld battery holders and otherparts.
An electric arc welder or mig welder that has at least 220 volts(and at least 100 amps of power output) should be used.
If you are not comfortable welding, you could ask someone youknow with welding experience to help, or you could hire aprofessional to do it for you. If you choose to do it yourself,please remember that you are dealing with hot metal. Be verycareful and be sure to wear protective clothing and weldingmask.
Alternatively you can bolt everything together, but welding ispreferred.
Parts list
Parts that will be used in making your electric car:
Amp meter shuntBattery endsBattery cablesBatteriesBattery shelves/holders (make your own)Cable cutters
A crimping tool to install cable endsChargerDC-DC power supplyE-Meter or several digital metersFusesInertia switchLugsMotor – AC or DCMotor controllerManual disconnectMotor adaptorMain contactorMiscellaneous nuts and boltsVacuum pump (to bleed power brakes)Throttle control box
Electric Vehicle (EV) Wiring Diagram
Below is a diagram of the electrical circuit of an electric vehicle.
(Diagram is not drawn to scale)
Chapter 1
Find a vehicle to convert
• We recommend a small vehicle for the conversion. A smaller
vehicle is lighter and therefore requires less power (andbatteries) to move.
A smaller vehicle (relative to a larger vehicle) will allow you totravel longer distances before having to recharge the batteries.
• You must find a car that has a manual transmission.
Automatic transmissions have energy losses that reduceperformance. Also, the shift points (revs) will not be appropriateon hills, and may damage the motor. Finally, the automaticrelies on an idling engine to keep the hydraulic pressure up.When an electric car stops at a stoplight, the motor stopsturning, and the transmission loses pressure. When the lightturns green, there is a delayed response to the throttle whilepressure builds up. (This could be dangerous)
• It is important to find a car that has a good body. Apart fromthe obvious visual appeal of a nice looking car, you want thecar to be safe, not full of rust etc. Your car may need to pass aroadworthy/vehicle inspection (depending on your countryand state).
• Look for a car that does not have a working motor. This willpush the price down. You are going to be removing the motorwhether it works or not, so there is no point paying extramoney for an unneeded working motor.
(If you do have a vehicle with a working motor, you could sell itto your local car scrapping/wrecking place, or you could placean ad in your local paper, or list the parts on ebay.)
There are many varied ways to find a car (meeting the abovecriteria) For example you can find plenty of bargains with online auctions such as http://www.motors.ebay.com/
Chapter 2
Electric motors
When converting your car to electric there are two choices: DCelectric motors and AC electric motors.
DC Motors
The DC motor will produce the power to run your car.
What you should be looking for is a “Permanent Magnet DCMotor”
The attributes of this motor that you need to pay attention to:
• Revolutions per minute (RPM) – Should be fairly low. (As ageneral rule of thumb, look for RPM under 400.)
• Shaft size – As a general rule of thumb, the shaft size should
be over 5/8 of an inch. This will insure that your DC motorhas adequate bushings to accommodate the constant spinning.
• Amps – A high current is good.
• Voltage – Should be at least 12 Volts. (As a general rule ofthumb, look for between 50 and 80 Volts.)
The average car requires a 20 horsepower motor to drive at aspeed of 50 miles-per-hour on a level surface (down thehighway for example.)
Horsepower will vary with volts and amps.
Below is some power conversion formulas that may help youunderstand how horsepower is calculated.
Amps x Volts = Wattswatts / Volts = Amps1000 watts = 1 kilowatt.75 kilowatts = 1 horsepower1 kilowatt = 1.34 horsepower
(Side note: You shouldn't technically compare electric motors togas engines. Electric motors and gas engines measure powerratings differently. Gas engines are rated at their peakhorsepower even though they can only maintain it for a fewminutes without overheating or breaking. Electric motors arerated at their continuous horsepower, which they can maintainindefinitely.)
DC motors can be connected directly to the transmission. Orthey can be connected to the drive axle. (If you choose thisoption, you need to use relay switches in order to go in reverse.)
Where you can buy a Permanent Magnet DC Motor:
• http://www.motors.ebay.com/ - Seller’s prices are normallyreasonable for DC Motors. You will find a mix of used andnew DC motors on ebay.
• Search the Internet. Go to google.com or your preferredsearch engine, and search for “Buy Permanent Magnet DCMotor” or “Permanent Magnet DC Motor (insert the name ofyour suburb, city or state)”
After a short time of searching, you should be able to find acompany selling them in your suburb, city or state.
• Ask at your local auto parts store.
You may be able to find a FREE or cheap DC motor, by:
• Asking around at scrap metal places. Companies regularly
scrap old machinery, which have DC motors.
• Asking businesses in your local industrial area.
Within an industrial center there will be manufacturing plants.Ask to speak with the maintenance or operations manager of themanufacturing plant. Ask the manager for their old DC motors.
Due to maintenance and capital depreciation schedules thesecompanies regularly replace (working) parts.
By asking the manager (or people with authority) politely andexplaining to them why you want the parts you will be surprisedhow many free parts (that the company no longer wants) youcan get.
• Asking a friend whom likes working on cars. They may have
access to one.
AC Motors
AC (alternating current) motors are just like the ones found inyour home appliances.
A motor controller mechanism (discussed in chapter 3) comesdirectly with an AC Motor.
One of the biggest advantages of AC motors is they can be usedfor braking.
The energy used in braking can be converted into power, tocharge your batteries. (This is called regenerative braking, andcan be found in all the new electric cars produced by the carcompanies.)
The regenerative capacity is built into the motor controller. Thisis why the AC motor and controller are sold as a package.
AC motors can produce much higher power ranges (longer
driving distances before re-charging the batteries) for the samesized motor when compared to DC.
Most AC motors are connected to the drive axle, however youcan connect them to the transmission.
The price of an AC motor can be much higher than a DC motor,but has its advantages of regenerative braking and higher powerranges.
If you are on a budget, we recommend DC. They are cheaperand can be used in any vehicle.
Chapter 3
Motor controllers
A motor controller is needed to convert proper voltage betweenthe battery and the motor. It controls the speed of the vehiclewhen you press the ‘gas’ pedal.
There are two choices of motor controllers: DC controllers
and AC controllers
DC Controllers
Smaller less expensive controllers are very limited and you canexpect slower acceleration. Ideally you should get a controllerthat is designed to handle over 100-volt battery storage.
At this range you will have acceleration to match or even gofaster, than an average gasoline vehicle. It should be noted thatwhen you get into this range, your performance increases (but sodoes the price).
AC controllers
As discussed previously, AC controllers come as a unit with anAC motor.
AC controllers have been designed to take the regenerativeenergy out of the braking to be used in charging the batteries.
If you choose an AC motor you will not need to find a separateAC controller.
Where you can buy controllers:
http://www.motors.ebay.com/http://www.beepscom.com/category_s/5.htmhttp://www.evparts.com/http://www.kta-ev.com/http://www.evmerica.comhttp://www.canev.comhttp://www.metricmind.com/http://www.cafeelectric.comhttp://www.grassrootsev.com/control.htmhttp://www.electricvehiclesusa.com/category_s/140.htmhttp://www.ev-america.com/
Where you can find a FREE controller
As discussed in chapter 2, you can find free or cheap parts(including motor controllers), by asking around at scrap metalplaces and businesses in local industrial areas.
Chapter 4
Batteries
Batteries are at the heart of your electric car. They are used tostore DC electricity.
There are three types of rechargeable battery suitable for electriccar use. Those types are lead-acid batteries, nickel metal hydride(NiMH) batteries, and lithium-ion (Li-ion) batteries.
Lead-acid
Lead-acid batteries are the oldest form of rechargeable batterystill in use. They've been used in all types of cars - includingelectric cars, since the 19th century. Lead-acid batteries are akind of wet cell battery and usually contain a mild solution ofsulfuric acid in an open container.
The major advantage of lead-acid batteries is they are wellunderstood and they have a low cost.
The have a recharge time of approximately 8 hours. They havethe lowest life cycle out of the batteries we are discussing.
Nickel metal hydride (NiMH)
They have a high energy density ie. a great deal of energy canbe packed into a relatively small battery.
When you use these batteries your driving range will beincreased (relative to lead-acid batteries).
These batteries don't contain any toxic metals so they're easy torecycle.
They are not as susceptible to heat and they have a shorterrecharging time (relative to lead-acid batteries)
These batteries are ideal over lead acid batteries, however thehigh cost is a major issue.
Lithium-ion (Li-ion)
Lithium-ion (Li-ion) batteries are even better than lead-acid &nickel metal hydride (NiMH) batteries
They have a very high energy density, are lightweight, have along battery life and are quick to recharge.
However they are extremely expensive.
If you are on a budget we recommend lead acid batteries. Theyare the easiest to obtain and they have the lowest cost.
When looking at particular types and brands of batteries youneed to consider these things:
• Weight – The lighter the battery the better.
• Amperage (amps) – The greater the amps, the longer yourdriving range will be.
• Maintenance – Is it required?
All the above factors will play a part in determining the price ofthe battery.
Batteries come in many sizes but try and look for batteries thathave at least a 20 hour rating, and have over 200 amps of powerusage.
You will need in the range of 20 batteries to run your vehicleeffectively.
As we mentioned, batteries can be expensive. In fact they can bethe biggest expense of your project.
How you can find FREE batteries:
Golf courses/shops
Golf cart batteries are recommended for electric carconversions.
Ask your local golf course manager if you could have their oldgolf cart batteries. They will probably be happy to give themaway, because otherwise they have to pay someone to removethem.
You might find that some of the batteries don’t work, howeveryou can revive (recondition) them.
How to revive these old batteries
About 4 out of 5 ‘dead’ batteries are just ‘sulfated’ ie. Sulfatecrystals have developed on the surface of the plates inside thebattery. This happens when the batteries are left in anundercharged state.
The batteries can be taken apart and cleaned, but it is verydangerous and needs to be done by a professional.
If you don’t want to pay a professional, we recommend youhave a look at the “Battery ReconditioningReport”. It teaches you how to revive batteries yourself safely.The creators of the report have a great knowledge of batteries.
You can take a look at it here:http://www.electricity4gas.com/batteryreconditioning.html
Another source of FREE batteries:
Industrial centers
Forklift batteries are also good for electric car conversions.
Find an industrial center and within it there will bemanufacturing plants.
Ask to speak with the maintenance or operations manager of themanufacturing plant. Ask the manager for their old forkliftbatteries.
Industrial forklift batteries are very expensive and last up to 20years. However due to maintenance and capital depreciationschedules, these companies generally replace the battery every 5years.
Battery Chargers
We recommend having a battery charger mounted in yourvehicle. This will allow you to recharge your vehicle anywhere,anytime.
You can not just use an off the shelf charger from the store.You will need a special battery charger.
Your charger should:
• Be adjustable to whatever battery voltage you are running inyour system.
• Shut off once your batteries are charged. (This is necessary toensure you do not end the battery life prematurely.)
Where you can buy batteries and chargers
http://www.beepscom.com/category_s/2.htmhttp://www.evparts.com/cat-Batteries+...+Street+Vehicle.htm#53http://www.canev.com/KitsComp/Components/Chargers.htmlhttp://www.metricmind.com/http://www.manzanitamicro.com/http://www.canev.com/KitsComp/Components/Chargers.htmlhttp://www.electricvehiclesusa.com/category_s/153.htm
Battery Safety
When determining where to place the battery housing (ie. wherethe batteries are kept), ensure the batteries are kept away from:
• electrical components, which can be a source of spark
• sources of heat or possible sources of open flame
Read all of the manufacturer's recommendations and warningsabout the safe use of batteries.
Chapter 5
In this chapter we take a closer look at the parts involved withyour electric vehicle conversion.
Connecting motor to drive train
After you take out the gas engine from your vehicle, you willneed to connect the electric motor to the drive train.
• Most of the recommended sources of motors come with an
adaptor kit. The kit makes it easy to attach the electric motorto the drive train.
The adaptor bolts to the transmission (or housing oftransmission) and the electric motor bolts to the other side.
The adaptor must be mounted with the correct spacing andaligned straight, so it will spin freely with the motor.
• A coupling device comes with the adaptor. The couplingdevice connects the motor shaft with the shaft of thetransmission.
Electrical circuits
There is a contact on the adaptor that runs from the motorcontroller. This is started with the ignition switch when you startyour electric car.
(Having a manual disconnect along this circuit, will ensure youwon’t get ‘zapped’ when you are working on your car.)
-----Tip for when dealing with electrical circuits and lines: Use asimple ammeter and voltmeter to measure power output and thecharging process.-----
Auxiliary system (lighting, radio etc)
To maintain your ordinary vehicle battery and your on boardelectrical systems (lighting, radio etc) there needs to be a simpleauxiliary 12 volt charging system.
A simple DC converter will take the high voltage of your largeDC motor and break it down to 12 volts.
OR (we recommend) mounting an alternator on the motorassembly. To do this, a simple adaptor unit can be purchasedthat will run your system at about 13.5 volts.
Fuses
All circuits should have fuses installed in line in case of a shortcircuit. We recommend having fuses installed in both positiveand negative feeds.
Fuses are crucial. If for some reason there was an extremeelectrical charge, you want the fuse to blow, not your engine orbatteries.
-----Convenience yip: Carry extra fuses with you in your car.-----
Connecting the batteries
You will need about 35 feet of battery cable. Use large cablesuch as 2.0 welding cable or bigger. It is flexible and large tocarry a lot of current.
The batteries connect to each other in series: negative (-) topositive (+) and positive (+) to negative (-).
Color-code your wire: red is positive and black is negative.
You will want to crimp the ends of the wire effectively and sealthem too with a cable end sealer to prevent leaks of current. Ifyou don’t seal the end, you will reduce your power and range.
-----Battery tip: When batteries are cold they hold about 50% oftheir regular charge.
It’s simple and cheap to install a heater in the car and a smallheater near your battery boxes to keep them warm.-----
The throttle (‘gas pedal’)
To make the car go, you put your foot on the pedal, the same asyou would in a gas car.
To make this happen, you need to mount a throttle box nearyour throttle control (gas pedal linkage).
Braking/Stopping
A small vacuum pump and a reserve tank for fluid is needed topower your brakes.
Chapter 6
In this chapter we get started with your electric vehicleconversion.
-----Tip before we start: Use a hoist for installing or removing heavyparts. Make sure you have a partner to help you throughout thisprocess.-----
Take measurements
The first step is to take and record various measurements. Oncethe engine is removed it may seem like there is plenty of space,but without proper planning it will quickly run out.
Removing wiring
Do not remove all the wires when you remove the gas engine.Some of the wires will be used when you install the electricmotor.
You must keep a proper record of where all the wires go. Youcould use a roll of tape, and attach it to the wires to help youkeep a record.
The following wiring must be kept:
• control wires and dash mount wires (they come in bundles)
• ignition wires
• coil wires
• starter wire
• speedometer wiring
Heavy ground wires can be removed.
Unneeded parts to take off your car:
• Remove the exhaust system. Your new electric car won’tproduce exhaust.
• Remove the fuel system and gas tank. They are no longerneeded.
Run your car empty of gas before removing. Gas is veryflammable, so be careful of sparks when removing the gas tankand the fuel lines.
• Remove the engine radiator and fans. They are no longer
needed.
• For now you need to remove the power steering pump and airconditioning. However make sure you keep them, becauseyou can re-install them later on (discussed in chapter 7).
• Remove the engine. Once you have unbolted the mounts, youcan remove the engine.
You will notice that you have to remove the engine at an angleso it can clear the engine compartment.
Before removing the engine, drain out all transmission fluid.
Parts to keep/the building process:
• Removing the transmission (temporarily): Once the engine isout, disconnect the transmission and install the electric motorand adaptor kit. Once the electric motor is mounted, you willreinstall the transmission, by bolting it to the transmissionmounts once again.
When reinstalling the transmission/motor assembly, measure thedistance from the flywheel to the engine block. You must keepthe same distance when hooking up the electric motor to thetransmission.
• The adaptor kit provides a coupler (joiner) to fit the flywheelto the rear shaft of your motor.
(You will need to remove the flywheel, which is attached to thetransmission first)
The coupler has a spacer that goes on first and this will providethe right distance to the housing for the flywheel.
• First you should fit the adaptor to the motor, then attach the
flywheel, then bolt on the clutch.
This whole assembly is then attached to the housing of thetransmission.
-----Side Note: How easy this process is depends on your type ofvehicle.
A rear wheel drive vehicle has more room under the hood.
The major vehicles used in conversions all have special adaptorsmade to do the conversion. Before deciding on what type ofvehicle you want to convert, we recommend you ask the opinionof the adaptor supply houses.
A few companies that sell adaptors:
http://www.grassrotsev.com/catalog.htmhttp://www.canev.com/http://www.evparts.com
-----
After this is completed you can put the whole motor andtransmission system back in the vehicle.
When placing it back in the vehicle, the motor/transmissionneeds to align (be at the same height) with the drive shaft.The transmission support members are then bolted back inplace.
Securing the motor/transmission assembly
The DC motor used is strong enough to move itself out ofposition, if it is not secured.
Commercial motor mounts are available for purchase, but youcan build your own for a fraction of the cost.
You can make a cradle assembly (frame), by welding a fewpieces of angle iron together. The frame can be bolted into themotor mount holes found on the DC electric motor.
When designing/making the frame, make sure all parts will fit,before you start welding. NEVER weld near the electric motor,as it will damage it.
Chapter 7
In this chapter we look at further steps involved in your electricvehicle conversion.
Battery placement
The batteries can go in the engine compartment or in the framesomewhere (back seat or trunk of car for example). If you areconverting a truck you can also place the batteries in the bed.
A few things to consider, when deciding where to place thebatteries:
• The closer the batteries are placed to the motor assembly theless wire is used.
• If you use lead acid batteries, they require monthlymaintenance. (You will need easy access to maintain them.)
• Consider if you have any passengers and their safety near thebatteries. (Sealed batteries are safer in the case of accidents orwith passengers close by.)
• You can place batteries in the trunk space effectively,however it reduces your hauling capabilities.
• After taking out the gas engine and installing the electric
motor, there will be spare space. You can place battery holderframes (and batteries) in this location.
However you can not take all the space with batteries, becausethe controller and charger also need to be mounted in this area.
• Batteries are heavy, so when you install them check how thecar suspension is handling the weight. Mounting the batteriesin various locations should help ‘balance it out’.
-----Side note: You should aim to have at least 20 batteries. Therange of your vehicle is determined by your battery capacity.The more batteries you have the longer you can travel betweencharges.-----
Building racks for your batteries
Regardless of where the batteries are placed you need to build arack/compartment to hold and secure them.
Steel, stainless steel or angle iron is recommended for thebottom plate to hold your batteries. Do some simple welding tocreate the edges that hold the batteries in.
You could easily find this material at rubbish tips or industrialyards.
Re-installing power steering pump & air conditioning
The power steering pump/system and air conditioning can beremounted. If you mount them just above the electric motor youshould be able to retain the original hoses from the former gasmotor.
These devices will run on a pulley system, powered by theelectric motor. The pulleys must align straight (kept on the samecenterline) or the belt will run off.
Take your time and use a small level to get it right.
You can usually use the same pulley assembly, which was usedon the old gas motor.
The pulley probably won’t fit immediately because the electricmotor shaft is a different size to the gas motor.
To overcome this problem you can grind the pulley (not theshaft) to make it fit.
Mounting other battery related parts
Plywood is recommended when building a rack for controller,contacts & battery charger.
You may want to consider a variation of a shelf design that fitsthe controller and battery charger in securely.
Placing the shelf/rack on slight tilt is recommended, so waterwill drain away and not sit on the surface.
When placing the components in your rack/shelf:
• Put the volt meter on top. Also put the charger on top so it iseasy to access, when you need to plug in a charge.
• Put the DC converter (that charges your 12 volt system) on
the bottom, along with the main contactor.
Above are just our suggestions of how to set yourwiring/electrical. Set it up however you think is practical.
Below is an example of a wiring diagram from an electricvehicle.
(Diagram is not drawn to scale)
Connecting the batteries
The batteries connect to each other in series: negative (-) topositive (+) and positive (+) to negative (-).
Color-code your wire: red is positive and black is negative.
Starting with the first battery connect positive to negative on thenext battery, and negative to positive, and so on.
As mentioned previously, you should use large cable such as 2.0welding cable or bigger. It is flexible and large to carry a lot ofcurrent.
(You will want to crimp the ends of the wire effectively and sealthem too with a cable end sealer to prevent leaks of current. Ifyou don’t seal the end, you will reduce your power and range.)
The cable is connected to each battery forming a series andfinally it is connected to the motor controller.
-----Safety tips & recommendations:
You are working with high voltages. We recommend:
• Using rubber ended tools
• Do not cross your tools across the battery terminals
• Never ground the wires, only connect them in series. In yourgas-powered car your electric supply is grounded, but this isnever the case with an electric car.
-----
After you have connected the series, you need to hook up yourremaining wires (the ones you marked earlier for easyidentification.)
If you are in doubt with any of the wiring, seek help from acompetent mechanical friend or automotive electrician.There is always a real danger when dealing with high voltagesof electricity, so please be careful.
Chapter 8
Final checks to make & steps to take
• Check that the throttle connections are working properly. Ifit’s not connected properly an error message will show. If it isset properly there is about 150 ohms of resistance necessaryto control the throttle.
• You can not have your foot on the gas pedal when you arestarting the vehicle or the controller interface will not openproperly. (This is a safety feature that prevents the vehiclefrom moving the instant it is turned on.)
• Check total voltage and the manual disconnect is set properly.
• Check all the fuses for correct installation.
• Use an e-meter to monitor the on board electrical andcharging system. The e-meter will tell you the voltage andamps being used.
• The light bulb test - The whole idea of this test is that if thereis a short in the system, the light bulb will take the currentand not your motor.
You need to wire a 100-watt light bulb to the positive lead of thebatteries in line with the circuit. Take an extension cord andwire a light socket in it.
The light should only turn on briefly and then go out. If it stayson then there is a problem that you have to fix, which is mostlikely a short in your wiring.
• Connect your final battery leads. Use gloves for thisconnection, as there will be a spark when the capacitors in theDC converter get charged up.
(Example) Under the hood of an electric car.
Congratulations it’s time to drive!
A few things to remember when driving an electric vehicle:
• When the car is stopped the power steering pump is notrunning. Easing on the power (‘gas’ pedal) will get it turningeasily.
• If you are stopped and need to turn the wheel just push in the
clutch, which disengages the transmission, and slowly pressthe power pedal and make your turn.
-----Final tips to keep the cost of your conversion low:
• Make sure you look for free and cheap parts from the sourcesmentioned in the manual.
• Consider purchasing other parts & supplies second hand.
• Sell the unneeded parts (such as gas motor & gas tank) youremoved from your vehicle to your local carscrapping/wrecking place, or you could place an ad in yourlocal paper, or list the parts on ebay.
-----
Chapter 9
Helpful Resources:
If you are seeking some assistance in converting your vehicle toelectric or want to learn more about electric vehicles, you couldjoin or ask for help from an Electric Vehicle Association.
Generally the members of Electric Vehicle Associations arehappy to help others, learn from each other, and advance thedevelopment of electric vehicles.
-----Please note that Electricity4Gas has no direct contact with theElectric Vehicle Associations listed. They have made noendorsement of Electricity4Gas.------
Links to various Electric Vehicle Associations are below:
Australia
Australian Electric Vehicle Assocation inchttp://www.aeva.asn.au/
Asia Pacific
Electric Vehicle Association of Asia Pacifichttp://www.evaap.org/
Europe
Electric Auto Association Europehttp://www.eaaeurope.org/
UK
The Battery Vehicle Societyhttp://www.batteryvehiclesociety.org.uk
Electric Auto Association– Arguably the biggest electric vehicle association in the world.http://www.eaaev.org/
Below are a list of Electric Auto Association chapters, split upinto countries and states & provinces.
(Thanks to http://www.eaaev.org/eaachapters.html for this list)
Canada
Electric Vehicle Council of Ottawa
Web Site: evco.caContact: Alan Poulsen <[email protected]>, (613) 271-0940Mailing: P.O. Box 4044, Ottawa, ON K1S5B1Meetings: 7:30pm-10pm, last Monday of the MonthLocation: The Green Room in the Canada Science andTechnology Museum, 1867 St. Laurent Blvd, Ottawa, 1867St.Laurent, Ottawa ONPlease check with guard for room location
Vancouver Electric Vehicle Association
Web Site: veva.bc.caContact: Haakon MacCallum <[email protected]>, (604) 527-4288Mailing: 4053 West 32nd Avenue, Vancouver BC V65 1Z5Meetings: 7:30pm, 3rd Wednesday of the month (Please checkweb site for details)Location:BCIT Electrical SE1 Bldg. Cafeteria — see map on
web site. All are welcome to join us beforehand (6pm - 6:30) atThe White Spot Restaurant, 4129 Lougheed Hwy, Burnaby, BC(North-East corner of Lougheed Hwy & Gilmore, 1st trafficlight East of Boundary & Lougheed).
Germany
EAA Deutschland
Web Site: eaa-deutschland.orgContact: Ruediger Hild <[email protected]>, 0049-6136-7520540Mailing: Forststr. 18, 66538 Neunkirchen/Saarland/DeutschlandMeetings: Please contact us for meeting times and locations
USA
Alaska
Alaska EAA
Web Site: alaskaEVA.orgContact: Mike Willmon <[email protected]>, (907) 868-5710Mailing: Attn Mike Willmon, 2550 Denali Suite 1, Anchorage,AK 99503Meetings: 8pm - 9pm, 3rd Friday of the monthLocation: Kaladi Brothers, Brayton Drive, Anchorage, AK99503
Arizona
Borderland Electric Vehicle Association
Contact: Donna Austin<[email protected]>, (520)432-5151Mailing: P.O Box 1222, Bisbee, AZ 85603Meetings: First meeting 5:30pm July 11th
Location: Copper Queen Library,6 Main Street, Bisbee, Arizona85603
Flagstaff EAA
Web Site: flagstaffeaa.org/index.htmlContact: Barkley Coggin <[email protected]>, (928)637-4444Mailing: 6215 Rinker Circle, Flagstaff, AZ 86004Meetings: 4pm - 6pm, 1st Sunday of the monthLocation: American Legion Hall on Birch and HumphriesStreets, Flagstaff, AZ
Phoenix EAA
Web Site: phoenixeaa.comContact: Jim Stack <[email protected]>, (480) 659-5513Mailing: Attn. Sam DiMarco, 1070 E. Jupiter Place, Chandler,AZ 85225Meetings: 9am, 4th Saturday of the month Location: Please seeweb site for location
Tucson EVA2
Web Site: teva2.comContact: Rush Dougherty <[email protected]>, (520) 240-7493Mailing: Rush Dougherty, 12800 W Big Valley St, Tucson AZ,85736Meetings: 9am, 3rd Saturday of the monthLocation: Room E, UMC, 1501 N Campbell Av, Tucson AZ,85724
California
Central Coast EAA
Web Site: eaacc.orgContact: Will Beckett <[email protected]>, (831) 688-8669
Mailing: 323 Los Altos Drive, Aptos, CA 95003Meetings: Call or see web site for meeting information.Location: Calvary Church, 8065 Valencia Street, Aptos, CA95003
Chico EAA
Web Site: geocities.com/chicoeaaContact: Chuck Alldrin <[email protected]>, (530) 899-1835Mailing: 39 Lakewood Way, Chico, CA 95926Meetings: 11am to 1pm, 2nd Saturday of the monthLocation: York Publishing/Videomaker 1350 E. 9th, Chico, CA95926 , one block west of 99E, corner of Bartlet & 9th St.
East (SF) Bay EAA
Web Site: ebeaa.orgContact: Ed Thorpe <[email protected]>, (510) 864-0662Mailing: 2 Smith Ct, Alameda, CA 94502-7786Meetings: 10am-12noon, 4th Saturday of the monthLocation: Alameda First Baptist Church, 1515 Santa ClaraAvenue, Alameda, CA
EVA of Southern California
Contact: Leo Galcher <[email protected]>, (949) 492-8115Mailing: 35 Maracay, San Clemente, CA 92672Meetings: 10am, 3rd Saturday of the monthLocation: Air Quality Management District(AQMD), 21865Copley Drive, Diamond Bar, CA (off Hwy 60 and Hwy 57)
Greater Sacramento EAA
Contact: Tim Hastrup <[email protected]>, (916) 791-1902Mailing: 8392 West Granite Drive, Granite Bay, CA 95746Meetings: 12noon, 3rd Tuesday of February, May, August, and
NovemberLocation: Cool River Pizza, 6200 Stanford Ranch Road,Rocklin, CA 95677
Konocti EAA
Web Site: konoctieaa.orgContact: Dr. Randy Sun <[email protected]>, (707) 263-3030Mailing: 800 S. Main Street, Lakeport, CA 95453Meetings: 11am, last Friday of the monthLocation: Sun Dental, 800 S Main Street, Lakeport, CA (Pleasesee our web site under Future Meetings for Up-to-date meetingtime and location.)
North (SF) Bay EAA
Web Site: nbeaa.orgContact: Chris Jones <[email protected]>, (707) 577-2391 (weekdays)Mailing: c/o Agilent Technologies, 1400 FountaingroveParkway, mailstop 3LSV, Santa Rosa, CA 95403Meetings: Typically 10am to 12noon, 2nd Saturday of themonth, check web site for detailsLocation: Please check web site for details
EVA of San Diego
Web Site: evaosd.comContact: Bill Hammons <[email protected]>, (858) 268-1759Mailing: 1638 Minden Drive, San Diego, CA 92111Meetings: 7pm, 4th Tuesday of the monthLocation: Regional Transportation Center, corner of El Cajon &I-15,, in the "Autotorium", San Diego CA
San Francisco Electric Vehicle Association
Web Site: sfeva.orgContact: Dale Miller <[email protected]>, (415) 491-0910
Mailing: 87 Mt. Tallac Ct., San Rafael, CA 94903Meetings: 11am to 1pm, 1st Saturday of the monthLocation: Luscious Garage, 459 Clementina Street, SanFrancisco, CA
San Francisco Peninsula EAA
Contact: Bill Carroll <[email protected]>, (650) 589-2491Mailing: 160 Ramona Avenue, South San Francisco, CA 94080-5936Meetings: 10am, 1st Saturday of the monthLocation: San Bruno Library, 701 Angus Avenue, San Bruno,CA
San Jose EAA
Web Site: geocities.com/sjeaaContact: Terry Wilson <[email protected]>, (408) 446-9357Mailing: SJEAA, 20157 Las Ondas San Jose CA 95014Meetings: 10am, 2nd Saturday of the monthLocation: Reid Hillview Airport -- 2500 Cunningham Rd. SanJose, Ca.
Silicon Valley EAA
Web Site: eaasv.orgContact: Jerry Pohorsky <[email protected]>, (408) 464-0711Mailing: 1691 Berna Street, Santa Clara, CA 95050Meetings: 3rd Saturday (Jan-Nov) mostly held at HP Palo AltoCA level ALocation: Bldg 20a Auditorium, Hewlett-Packard, 3000Hanover St Palo Alto CA
Ventura County EAA
Web Site: geocities.com/vceaaContact: Bruce Tucker <[email protected]>, (805) 495-1026
Mailing: 283 Bethany Court, Thousand Oaks, CA 91360-2013Meetings: Please contact Bruce for time and location
Florida
Florida EAA
Web Site: floridaeaa.orgContact: Shawn Waggoner <[email protected]>, (561) 543-9223Mailing: 8343 Blue Cypress, Lake Worth, FL 33467Meetings: 9:30am, 2nd Saturday of the monthLocation: Coastal Tire and Auto, 35 SW 1st Avenue, BocaRaton, FL
Georgia
EV Club of the South
Web Site: evclubsouth.orgContact: David Kennington<[email protected]>,(770) 944-3066Mailing: 897 Woodman Trail, Austell, GA 30168Meetings: 6pm, 1st Wednesday of the monthLocation: please check our web site Calendar for locations.
Idaho
Panhandle Electric Vehicle Association
Contact: Gordy Ormesher <[email protected]>, (208)660-8539Mailing: 2025 E. Foxborough Court, Hayden, ID 83835Meetings: 6:30pm, 2nd Monday of the monthLocation: Go Green Electric, Post Falls, ID
Illinois
Fox Valley EAA
Web Site: fveaa.orgContact: Ted Lowe <[email protected]>, (630) 260-0424Mailing: P.O. Box 214, Wheaton, IL 60189-0214Meetings: 6:30pm, 3rd Friday of the monthLocation: Packer Engineering, 1976 N Washington St,Naperville, IL 60563
Kansas
See Mid America EAA Kansas City, MO
Massachusetts
New England EAA
Web Site: neeaa.org/Contact: Bob Rice <[email protected]>, (203) 530-4942Mailing: 29 Lovers Lane, Killingworth, CT 06419Meetings: 2pm-5pm, 2nd Saturday of the monthLocation: Please contact us for location
Pioneer Valley EAA
Web Site: pveaa.orgContact: Karen Jones <[email protected]>Mailing: P O box 153, Amherst, MA 01004-0153Meetings: 2pm, 3rd Saturday of the month (Jan - June; Sept -Nov)Location: Please contact us for location
Michigan
Michigan EAA
Coming Web Site: michiganEAA.orgContact: Larry Tuttle <[email protected]>, (734) 995-9904Mailing: 1620 Baldwin Ave, Ann Arbor, MI 48104Meetings: Please contact us for meeting information
Minnesota
Minnesota EAA
Web Site: mneaaev.wikidot.comContact: Craig Mueller <[email protected]>, (612) 414-1736Mailing: 4000 Overlook Drive, Bloomington, MN 55437Meetings: 7pm to 8:30pm, Last Thursday of each month, CDTLocation: Location changes, please check web site for details
Missouri
Mid America EAA
Web Site: maeaa.orgContact: Mike Chancey <[email protected]>, (816) 822-8079Mailing: 1700 East 80th Street, Kansas City, MO 64131-2361Meetings: 1:30pm, 2nd Saturday of the monthLocation: Location changes, please check web site for details
Gateway Electric Vehicle
Web Site: gatewayev.orgContact: George Moellenhoff <[email protected]>, (314)963-1358Mailing: 741 Eckrich Place, St. Louis, MO 63119Meetings: Monthly, Please contact us for for details
Nevada
Alternative Transportation Club, EAA
Web Site: electricnevada.orgContact: Bob Tregilus <[email protected]>, (775) 826-4514Mailing: 2805 W. Pinenut Ct, Reno, NV 89509Meetings: 6pm, Monthly, see web site or call for detailsLocation: Northwest Reno Library, 2325 Robb Drive, Reno, NV
Las Vegas Electric Vehicle Association
Web Site: lveva.orgContact: William Kuehl <[email protected]>, (702) 636-0304Mailing: 2816 El Campo Grande Avenue, North Las Vegas, NV89031-1176Meetings: 10am to 12noon, 3rd Saturday of the monthLocation: Clark County Library, 1401 E. Flamingo Rd, LasVegas, NV
New York
Long Island Electric Auto Association
Web Site: lieaa.org/homeContact: Michael Anzalone <[email protected]>, (631) 944-1104Mailing: 18 Garwood Street, Centereach, NY 11720Meetings: 6pm, 1st Wednesday of the monthLocation: Lupton Hall at SUNY Farmingdale, Farmingdale,NY
North Carolina
Coastal Carolinas Wilmington
Contact: Page Paterson <[email protected]>, (910) 686-9129
Mailing: 1317 Middle Sound, Wilmington, NC 28411Meetings: Please contact us for time and date
Piedmont Carolina Electric Vehicle Association
Web Site: opecthis.infoContact: Clifford Metcalf <[email protected] >, (704)624-3397Mailing: 1021 Timber Wood Ct, Matthews, NC 28105Meetings: Please contact us for time and dateLocation: Charlotte Energy Solutions, 337 Baldwin Avenue,Charlotte, NC
Electric Cars of Roanoke Valley
Contact: Harold Miller <[email protected]>, (252) 534-1258Mailing: 567 Miller Trail Jackson NC 27845Meetings: Please contact us for time and dateLocation: Economic Development Building in Jackson, NC
Triad Electric Vehicle Association
Web Site: localaction.biz/TEVAContact: Jack Martin <[email protected]>, (336) 213-5225Mailing: 2053 Willow Spring Lane, Burlington, NC 27215Meetings: 9am, 1st Saturday of the monthLocation: T.S. Designs, 2053 Willow Spring Lane, Burlington,NC
Triangle EAA
Web Site: rtpnet.org/teaaContact: Peter Eckhoff <[email protected]>, (919) 477-9697Mailing: 9 Sedley Place, Durham, NC 27705-2191Meetings: 3rd Saturday of the monthLocation: Advanced Energy, 909 Capability Drive, Raleigh, NC
Oregon
Oregon Electric Vehicle Association
Web Site: oeva.orgContact: Rick Barnes <[email protected]>,Mailing: 19100 SW Vista Street, Aloha, OR 97006Meetings: 7:30pm, 2nd Thursday of the monthLocation:PCG Building, Two World Trace Center, SW cornerof 1st and Salmon, Portland
Pennsylvania
Eastern Electric Vehicle Club
Web Site: eevc.infoContact: Peter G. Cleaveland <[email protected]>, (610) 828-7630Mailing: P.O. Box 134, Valley Forge, PA 19482-0134Meetings: 7:00 p.m. 2nd Wednesday of the monthLocation: Room 35, Plymouth-Whitemarsh High School, 201 E.Germantown Pike, Plymouth Meeting, PA
Three Rivers EVA
Web Site: threeriverseva.orgContact: Jonathan Belak <[email protected]>, (724) 387-8210Mailing: 5847 Washington Avenue, Export, PA 15632-1331Meetings: 10:00 a.m. 3rd Saturday of the monthLocation: PA Electrics, 5847 Washington Avenue, Export, PA
Texas
Alamo City EAA
Web Site: aceaa.orgContact: Alfonzo Ranjel <[email protected]>, (210) 389-2339
Mailing: 9211 Autumn Branches, San Antonio TX 78254Meetings: 3:00 p.m. 3rd Sunday of January, March, May, June,July, August and OctoberLocation: Please subscribe to mail list at ACEAA.ORG forlatest update.
AustinEV: the Austin Area EAA
Web Site: austinev.orgContact: Aaron Choate <[email protected]>, (512)524-7159Mailing: PO Box 49153, Austin, TX 78765Meetings: Please see our web site
Houston EAA
Web Site: heaa.orgContact: Dale Brooks <[email protected]>, (713) 218-6785Mailing: 8541 Hatton Street, Houston, TX 77025-3807Meetings: 6:30pm, 3rd Thursday of the monthLocation: Room 280, 2nd Floor, The Citizen EnvironmentalCenter, 3015 Richmond Avenue, Houston, TX
North Texas EAA
Web: http://nteaa.org/Contact: John L. Brecher <[email protected]>, (214) 703-5975Mailing: 1128 Rock Creek Drive, Garland, TX 75040Meetings: 2nd Saturday of the monthLocation: Time and Place for the upcoming meeting is posted atthe NTEAA Yahoo Group
Utah
Utah EV Coalition
Web Site: saltflats.com. Utah Salt Flats Racing Associationmeeting (USFRA); we are the Official Bonneville Salt Flats AFRacing Events Coordinators.Contact: Kent Singleton <[email protected]>, (801) 644-0903Mailing: 325 E. 2550 N #83, North Ogden, UT 84414Meetings: 7pm, 1st Wednesday of the monthLocation: Totems Restaurant, 538 S. Redwood Rd, Salt LakeCity, UT, (801) 975-0401. You'll meet BYU Electric Team,WSU-EV Design Team other land speed racing celebrities.Always a great turn out.
Washington
Seattle Electric Vehicle Association
Web Site: seattleeva.orgContact: Steven S. Lough <[email protected]>, (206)524-1351Mailing: 6021 32nd. Ave. NE, Seattle, WA 98115-7230Meetings: 7pm, 2nd Tuesday of the monthLocation: 4310 Thackary Place, Seattle, WA Please see our website for details
Washington D.C.
EVA of Washington DC
Web Site: evadc.orgContact: David Goldstein <[email protected]>, (301) 869-4954Mailing: 9140 Centerway Rd, Gaitherburg, MD 20879-1882Meetings: 7pm, 2nd or 3rd Tuesday of the monthLocation: National Institute of Health, building 31-C, 6th FloorBethesda MDPlease check our web site for current information
Wisconsin
Southern Wisconsin EV Proliferation
Web Site: emissionsfreecars.comContact: Mike Turner <[email protected]>,(920) 261-7057Mailing: 808 Fieldcrest Ct, Watertown, WI 53511Meetings: Please contact us for date and location
Chapter 10
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