eVan
 EVanagon - Conversion Details

March 10th, 2007 - First Drive!  See the Movie, and listen to the birds.  


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Descriptions
Data
 Performance
 Parts Listing
Suppliers
System Description
Basic Specs
Donor Vehicle: 1980 Vanagon
Duration of Conversion: 9 months start to first drive
Batteries: 28 Deka 8g24's, 74 Ahr (c20), 12 volt, 52 lbs each
Motor/Controller: 3 phase induction w/regen, 80 kW
Weight: guess at 4400 lbs (5200 GVW), orig. empty weight 3500 lbs
Cost: lots
Range: ~40 miles
Average consumption: 450 kW/mile (wall to wheel)
Acceleration: More than stock


Check out some of the pictures:
Pic set 1
Pic set 2
Pic set 3

Initial Specification
  • Donor Vehicle Selection
  • Motor/Controller Selection
  • Charger selection
  • Battery Selection
 Non-EV Related Items
  • De-campering of the vehicle (patch up holes)
  • Painting the vehicle
  • Work area - the "garage"
Passenger Area Battery Boxes
  • Battery Placement - height and front/back distribution
  • Cutting battery box holes
  • Welding the battery boxes
  • Re-routing the E-brake
  • Re-routing the main hydraulic brakes
  • Manual Trans Shift mechanism
  • Mounting the boxes - welding and bolting
  • Sealing the boxes
  • Making the box lids
  • Painting
 Engine Compartment 
  • Motor mounts
  • Motor to tranny adapter
  • Battery mounting above tranny
  • Battery mounting either side of motor
  • Water spray minimization to high power electronics
  • Air cooling to components
Miscellaneous Items
  • Battery heaters
  • Operator controls 
  • Wheel lockout 
 Vacuum system for power brakes
  • Pressure switch and relay
  • Brackets
  • Pump and resevoir
  • Vacuum connection
Main Power Handling
  • Fuses and breakers
  • (non) contactors
  • Cable and lugs
  • Routing - mechanical robustness
  • Pwr distribution box (controller, charger, volts measure, current measure)
  • Accessory power supply line
  • Measurement supply lines
 DCS (Digital Control System)
  • Battery temperature monitoring
  • Battery voltage monitoring
  • Data system
  • Puppy Linux
  • GPS - DMM
  • Relay module
  • Routing power wires
  • Routing the signal wires
  • Soldering all of the components
  • Controller communication
  • Charger communication
Auxillary Power
  • DCDC Converter
  • Opperating modes
  • Box layout and design
  • PV module place holder
 TBD's
  • Cabin Heater
  • Roof PV
  • Long Range Power
  • Carpet
  • Rear/Side Seats
  • Tires
  • Upgraded suspension
  • Stereo
Analysis of the Effort
  • What tools were needed and most useful (MVT)
  • How I spent my time (inside and outside)
  • How it would be quicker the second time.

Random and Dissorganized Links (someday to orgnize):


http://www.evalbum.com/
www.seattleeva.org
www.canev.com
http://www.kta-ev.com/
http://www.electricvehiclesusa.com/
http://jerryrig.com/convert/
www.evparts.com
http://www.ev-supply.com/
Battery Powered Systems: http://www.beepscom.com/
Electric Vehicles USA: http://www.electricvehiclesusa.com/
https://evsupply.cartfly.com/evsupply 
http://www.electricmotorsport.com/


Good News and General EV Info:

http://news.gmane.org/gmane.recreation.cars.evdl
http://www.autobloggreen.com/
http://www.evworld.com/
http://autos.groups.yahoo.com/group/electric_vehicles_for_sale
http://plugsandcars.blogspot.com
http://www.automanifesto.com
http://www.energydestination.com
http://blog.seattlepi.nwsource.com/electricvehicleguide/index.asp
http://www.electricdrive.org/

 http://www.kiwiev.com
http://www.bev.com.au/index.html



UltraCaps

       Education and Outreach:
       KiloFarad International
       www.kilofarad.org
      
       Manufacturers:
       Europe: EPCOS
       www.epcos.com/web/home/html/home--e.html
      
       Japan: Okamura Laboratories; JEOL
       www.okamura-lab.com
       www.jeol.co.jp
      
       Russia: ESMA-capacitor
       www.esma-cap.com
      
       South Korea: NESS Capacitor Company
       www.nesscap.com/index.html
      
       U.S.: Maxwell Technologies
       www.maxwell.com/ultracapacitors/index.html





Good Info on Crushing vs. Converting
http://www.calcars.org/calcars-news/1007.html

Nifty battery sites
http://www.ener1.com/enerdel.html
http://www.nilar.com/index.php?pageID=33&languageID=1

http://www.aortacity.se/Items/Li-jonTillverkare.htm


DIY Sites
http://www.physclips.unsw.edu.au/jw/electricmotors.html
http://www.evalbum.com/1529
http://www.zeva.com.au/tech/controller_design/
http://nuancesystems.net/mk1_power.shtml
http://www.evdl.org/lib/mh/index.html
http://liionbms.com/php/bms_options.php
http://enviromotors.com/wiki/index.php/Main/HomePage

Contact: insolation@mac.com Made with Nvu