Motor InstalledThe Starting point..Rear Battery AccessCompletedVehicle LiftCharger MountedAll cleaned up & raedy to go...More....more....
OwnerCraig Vinton
Owner's Other EV1994 Chevrolet S-10
LocationSeattle, Washington US map
Web/EmailWebPage email image
Vehicle1996 Geo Tracker
MotorAdvanced DC FB1-4001A Series Wound DC
Purchased from KTA Services.
DrivetrainRear wheel drive with 5-speed and clutch. Normally driven in second gear when hilly and third gear on flats.
ControllerCurtis 1231C-8601
Purchased from KTA Services. Mounted on 3/8" thick aluminum plate with heat transfer paste.
Batteries10 Trojan T-1275, 12.00 Volt, Lead-Acid, Flooded
Purchased from Allied Battery in Seattle. Battery connections are 2-0 welding cable with crimp on lugs.
System Voltage120 Volts
ChargerRussco SC 18-120 SO
Purchased from EV Parts.
HeaterMES-DEA RM4 fluid heater with integrated pump from Metric Mind. This pumps through the stock heater core.
DC/DC Converter Go Power GPC-45
This is exactly the same as the Iota DLS-45. Purchased from a company called Outside Supply.
InstrumentationAdded two 1.5" Yokogawa panel meters, one for voltage and one for amperage. Also added lights to annunciate the closure of the motor thermal switch. Curtis 900R battery fuel gauge.
Top Speed60 MPH (96 KPH)
I have gotten to 60mph in fourth gear on the freeway (flat).
AccelerationReasonable.
Range25 Miles (40 Kilometers)
I can drive around 25 on normal Seattle grades. I think that it would go 30+ in a more flat environment.
EV Miles
Start:107,500 Miles (172,967 Kilometers)
Current:107,800 Miles (173,450 Kilometers)
Total:300 Miles (482 Kilometers)
Seating CapacityOriginal seating for 5.
Curb Weight3,380 Pounds (1,536 Kilograms)
Certified Scale Weight. GVWR listed at 3420.
TiresNew Goodyear Integrity 205/70R15's at 44psi (1819 load rating).
Conversion TimeBegan 7/3/07, substantial completion date 9/8/07. Worked mostly on weekends and at night. Estimated 96 hours of work.
Conversion Cost$10,500. Vehicle originally purchased for $450 with a blown head gasket.
Additional FeaturesThe adapter plate was cut from plate steel, with a ring of 6" pipe welded between two flanges to provide an area for the motor shaft and coupler. The coupler was machined locally with a setscrew/keyway configuration. Motor shaft was dimpled with a drill bit and blue thread locker applied to setscrews.

There are six batteries located where the fuel tank used to be. If the carpet is pulled up, there is a plastic access cover that allows access to the batteries for connections and watering. If the batteries need replacement, the whole rack can be lowered with a jack after being unbolted, or the batteries can be individually removed.

The other four batteries are located under the hood, with three as high above the motor as they could physically go, and with the fourth located all the way at the front and as low as possible. ABS plastic was attached to the underside of the hood to prevent battery shorts if they were to come loose of their hold downs.

I used two Albright solenoids to kill the main power, one on each leg of the 120V system. The negative leg closes when the keyswitch is turned to the ignition position, providing negative to each of the 120V devices. The positive leg is always connected to the fluid heater and DC/DC converter, but only closes to the controller when the interlock circuit is completed. The interlock circuit only allows the motor to run if the key is in the ignition position, the start latch is activated (by turning the key to the start position), the throttle is depressed, the clutch is not pushed in, the parking brake is not on, and the charger is not plugged in. The controller also has a high pedal disable to prevent the car from starting with the throttle down.

Electric vacuum pump by SSBC ordered from Auto Anything, normally designed for hot rods with insufficient engine vacuum.

My first task was replacing the power steering rack with a manual one.

The rear springs were replaced with units made by Old Man Emu, hence the nickname. They were sold by an internet 4WD retailer called Rocky Road. Old Man Emu only makes springs for off road vehicles, which includes the Geo Tracker, though I have the 2WD version.

code by jerry