OwnerDavid Harrington
LocationActon, Massachusetts US map
Web/EmailWebPage email image
Vehicle1996 Honda Civic LX
This is a great little car that has earned the name "Putt-Putt" because it is the smallest car at the house.
MotorAdvanced DC FB1-4001A Series Wound DC
9.1" Beast of a motor!
DrivetrainAutomatic 4 Speed Electronically Controlled Transmission
ControllerKelly KDH09401
This is the Kelly Controler KDH09401 with REGEN, but it is disabled because my motor is not PM.

Zilla 1K-LV is on it's way.
Batteries8 Everstart MAXX29, 12.00 Volt, Lead-Acid, Flooded
The Everstart MAXX29 DC @ 125Ah, 210 Reserve Capacity, 65 LBs and manufactured by Johnson Controls.
System Voltage96 Volts
ChargerK and W BC-20
Adjustable Charger Set to 10 AMPs charging current.
Heater1500 Watt Ceramic Heater placed on the passenger's seat and used to defrost/preheat the car in the morning. Thinking about putting the Zilla's water cooling through the heater core for winter heat while driving.
InstrumentationPakTrakr, AMP Gauge
Top Speed55 MPH (88 KPH)
Driven 35-45 MPH mostly.
AccelerationDecent in the flat roads, it dies on hills of any incline.
Range20 Miles (32 Kilometers)
Estimated 20 miles to 80% DoD based upon 14 mile drives and a little more than half pack left over going 35 MPH or less. Hills and Temp have been cutting into that range.
Watt Hours/Mile250 Wh/Mile
EV Miles
Start:243,065 Miles (391,091 Kilometers)
Current:244,130 Miles (392,805 Kilometers)
Total:1,065 Miles (1,713 Kilometers)
 
    As of 11/12/2009
Seating Capacity5 Adults
Curb Weight2,700 Pounds (1,227 Kilograms)
TiresToro Radial Touring Reduce Rolling Resistance, came with the donor.
Conversion TimeAbout 120 Hours of research so far.
3 Hours so far on Charger system.
40 Hours on Controller Research/Prototyping
2 Hours Desiging Motor Coupler
20 Hours removing parts/designing brackets
8 Hours installing components

Conversion Cost$3200 before Zilla 1K-LV
Additional FeaturesPower Steering and A/C will be hooked up to the second shaft on the FB1-4001A motor. Power Brakes are using a Thomas Vacuum Pump from eBay.
This is my first conversion, and it's on a really small budget.I now have all my parts and I hope to have the engine out in the coming weeks while waiting for the coupler to be machined. Check out my website for updates!!

I have the goal of 35 miles at 40 MPH, but I believe my commute has a 35 MPH speed limit or less for the entire thing.

The motor may be on the small side, but all I am going for is a gas-free car that gets me around town. I plan on driving back roads anyways since the highways around here are crazy. I will be adding a blower cooling system to the little sucker and squeeze as much power as possible out of it.

60 Volt Test: The K99-4007 is very underpowered at 60 volts, but was still fun to drive around!

I did a 96 volt test and the power was decent and it was dead quiet. I haven't taken it past 25 MPH yet since the vacuum brakes aren't installed yet.

12-19-08 I did my first real drive, 6.2 miles in 20F weather, and lots of hills with batteries that were not fully charged. The first half of the trip was 30-35 MPH, second half was 20-25 MPH.

1-5-09 It's finally legal! Drove 6.2 miles round trip in 25F weather with power to spare.

1-13-09 Installed my PakTrakr and drove 4.9 miles. The batteries were mostly charged but cold. PakTrakr read 56% after the hilly journey, this cold is AWFUL on the batteries!

2-12-09 I drove 11.4 miles on a single charge, and checked the water levels.

2-17-09 I installed a K&W BC-20 charger for faster charge times. I also bought a 9.1" FB1-4001A motor that I will be installing.

3-7-09 I have about 135 EV miles on the K99-4007, which got pulled today. FB1-4001A going to the machine shop for new plans and should be installed by the end of the month.

6-14-09 The FB1-4001A has finally been installed and tested. Ranges and performance tests will start soon.

7-22-09 The FB1-4001A is in! It has been a daily driver for a while, but the Kelly doesn't hold up to these MA hills so it will be replaced soon once the funds allow it.

8-23-09 I have ordered the new Synkromotive controller and hope to get it mid to late September. I also had two batteries go bad which got replaced under warranty.

9-9-09 I have over 800 miles on the EV so far and I insulated the batteries because the cold weather was cutting into my range in the morning commute. I have also experienced some problem in getting my new Synkromotive controller, so I am considering upgrading to a Zilla and have it in a few weeks.

9-24-09 I had to install all new brakes, rotors, drums and shoes this past week due to them locking up. I did order up a Zilla 1K-LV and how to be getting it in mid to late October.

11-12-09 After 244,130 miles the transmission died. I have a new one and I am in the process of installing it but having problems with the bolts on the lower control arms.

code by jerry