Electrics box innardsRear viewGeneratorFlywheel
OwnerBill Vogan
LocationKettle Falls, Washington United States map
Vehicle1984 Ford Ranger
short box, regular cab
MotorAdvanced DC FB-4001 Series Wound DC
DrivetrainClutch was removed about a year ago. Had flywheel turned down to just the size of clutch disc minus lining. Drilled and tapped it to bolt inner hub. Don't need no stinkin' clutch!
ControllerCurtis 1231C-8601
Curtis is doing well in this conversion. I barely hear the 1.5khz in the vehicle. Louder outside people say. Very nice slow speed control.
Batteries20 US Battery US-125, 6.00 Volt, Lead-Acid, Flooded
They have served me well, but are in need of replacement now.
System Voltage120 Volts
ChargerRussco sc-50
New SC-50 will reside under hood. 2-pole GFI behind seat with conduit to motor bay. I will have an update on the new unit soon.
Heater1500 watt in stock heater box
DC/DC ConverterIota 45
A real nice converter for the price. No complaints. I leave it on all the time to keep my aux battery charged. Uses almost no current when idle.
InstrumentationWestberg amps,volts. VDO aux volts. Motor over-temp led. Elcon fuel gauge
Top Speed75 MPH (120 KPH)
Has gone 70, at about 350 amps!
AccelerationPretty snappy for 25 hp!
Range50 Miles (80 Kilometers)
Record is 53 miles at 35-40 mph
Watt Hours/Mile315 Wh/Mile
This is probably as good as it will get. About 3500 miles on the conversion now. (figured at 55 mph)
EV Miles
Start:2,000 Miles (3,218 Kilometers)
Current:13 Miles (21 Kilometers)
Total:-1,987 Miles (-3,196 Kilometers)
    As of 3/26/2011
Seating Capacity3 adults
Curb Weight4,000 Pounds (1,818 Kilograms)
Gained about 250# when generator was added.
Conversion Time4 months
Conversion CostAbout 10k with batteries
Additional FeaturesAnderson 350 amp disconnect at rear pack. All electrics housed in aluminum box. Clarion stereo w/4 speakers. I used a relay-activated precharge circuit for the Curtis with the recommended resistor. Added a "precharge confirm" neon pilot lamp to verify precharge and circuit integrity. Takes about 3 seconds from "switch on." Neon light stays on until controller caps discharge below 90 volts or so. I also wired the motor overtemp sensor to a red led on the dash, and used the "start" position of the ignition switch as a test for the circuit. 1500 watt electric heater replaces water core in stock heater.
3/26/11 Just finished major upgrades. Entire charger interface has been upgraded to 240 volt Russco SC-50 located under hood. 2-pole gfi behind seat feeds charger via rigid 1/2" emt. Elcon fuel gauge added also. It's time for new batteries now, not sure how that will be handled yet. Onboard 35 amp generator was added about a year ago. At one point I went 75 miles on about 1.5 gal of gas. Genny is a 7.5 hp 3-phase motor reconfigured to delta to lower it's voltage, 3-phase rectifier and capacitors with 16 hp engine. Remote choke, ignition, and electric start allow full operation from cab. Not quite as elegant as the Volt, but it does extend the range and prevents deep discharges on the pack. Came a little late for this pack though!

code by jerry