OwnerJens Rekker
LocationDunedin, Otago New Zealand map
Web/EmailWebPage email image
Vehicle1989 Ford Courier
Typical tradesman's utility in New Zealand.
MotorAdvanced DC XP1263A Series Wound DC
Experimental 8" ADC motor, no longer in production.
DrivetrainCustom clutch mounting onto lightened flywheel plate and milled steel adapter plate onto bell-housing (Adrian Mulder Precision Engineering). Manual (Standard) 5-speed transmission (transaxle).
ControllerCurtis 1221 PO51
96V to 144V model, 500A, no longer in production. Makes the same whining noise as a Curtis 1231C, probably related.
Batteries24 Exide ED105, 6.00 Volt, Lead-Acid, Flooded
Exide clone of the Trojan T105. Much more available and less expensive in this country. C20 capacity about 215 Ah individually, and 31 kWh as a pack.
System Voltage144 Volts
ChargerZivan NG3 144-15
240 VAC, single phase model
HeaterNot decided. Probably ceramic element embedded in heater core.
DC/DC ConverterIota DSL45
InstrumentationVoltmeter
Ammeter
Curtis 900R "Fuel Gauge"
Top Speed60 MPH (96 KPH)
(100km/hr) Much faster than that, I'm not interested in going.
AccelerationAbout the same as before conversion. The faster you accelerate, the facter the amps pile on though!
Range60 Miles (96 Kilometers)
(100km) Estimated. Yet to test range.
Battery pack still needs to be broken in.
Watt Hours/Mile280 Wh/Mile
Power consumption trials still ongoing.
EV Miles
Start:169 Miles (271 Kilometers)
Current:169 Miles (271 Kilometers)
Total:0 Miles (0 Kilometers)
 
    As of 5/18/2008
Seating Capacity3 friendly adults across bench seat.
Curb Weight4,000 Pounds (1,818 Kilograms)
Original 3,100 lbs (1400 kg). Removed about 900 lbs (400 kg). Added about 1760 lbs (800 kg). So, probably weigh in at 4000 lbs (1800 kg)
TiresPirelli Chrono P3000 LRR tyres
850 kg per tyre weight capacity
70 psi pressure rating.
Conversion Time5 months.
Conversion CostAbout $11,000US.
I've been lucky enough to source a lot of new parts locally in New Zealand or Australia, plus a second-hand motor and controller from Auckland. Otherwise, the shipping costs would have severely inflated the total.
Additional FeaturesManual steering standard (no power steering requirement).

Electric vacuum pump and reservoir brake assist (EVParts).

Steel well-side deck / tray removed and replaced with tube steel - wood flatdeck (table-top) for weight savings.

18 x back battery rack goes full width behind cab as two rows of 9 batteries fitted lenghtwise. Leaves 6 foot length of flatdeck for carrying payload.
The choice of donor vehicle was dictated by the strict vehicle certification and inspection requirements in New Zealand for modifications of any kind. The Ford Courier recommended itself by the wide gap between the curb weight and Gross Vehicle Mass / Maximum (GVM) rating allowing the additional weight of the battery pack and a good payload following conversion. The battery packs could also be placed outside any zone considered the 'passenger compartment', simplifying battery clamp-down and gas venting certification requirements. We also wanted reasonable range for our commuter EV, so that we could stray a bit further from the city limits if we wanted to.

The standard New Zealand 240 VAC house voltage eases the difficulty of finding an outlet for opportunistic charging. We will need to use a 15A (fat earth pin) plug top and socket.

New Zealand derives over 70% of national electrical power from renewable sources, such as hydro, wind and geothermal. So, it is a good place to gain the best benefit to the atmosphere of displacing gasoline.

code by jerry