OwnerScott Samuel
LocationCorvallis, Oregon US map
Vehicle1986 Toyota MR2
MotorAdvanced DC FB1-4001-A Series Wound DC
9-inch with auxiliary shaft
DrivetrainOriginal 5-speed manual transmission, clutchless design (through EV America).
ControllerCurtis 1221C
max 400 Amp
Batteries16 Trojan T-125, 6.00 Volt, Lead-Acid, Flooded
deep-cycle, total weight about 1050 pounds.
System Voltage96 Volts
ChargerRussco SC 30-120 SO
I added a voltmeter to allow more accurate charging. It took many months (over seven!) to get a manufactured charger. In the interim I used a homemade "Bad Boy" variac charger based on Ben Fratto's design. 60% power factor. Provides 15 Amps DC at 25 Amp AC draw from 110 VAC outlet.
Heater1KW electric placed in original heater core enclosure--barely warm enough to defrost, but not enough to heat the driver.
DC/DC ConverterAstrodyne SD-350D
Provides 30 Amp @14VDC. I use it to charge a 12V lawn-tractor battery. Time will tell if this is an adequate arrangement.
InstrumentationVoltmeters (0-150 VDC; 0-20 VDC),Ammeter (0-400 Amp), Speedometer, Tachometer
Top Speed63 MPH (101 KPH)
So far (with car in 4th or 5th gear); batteries are still being broken in.
AccelerationPoor, but adequate for my needs at present.
Range67 Miles (107 Kilometers)
For 80% DOD at mostly 35-45mph, with brief hills and a short distance at 55mph. Range is 41 miles for 50% DOD.
Watt Hours/Mile307 Wh/Mile
I estimated based upon batteries' charging rate--my car's ammeter measures motor current, not battery current, so I can't do "live" measurements while driving. The speed is averaged (actually going from 25 to 55 at various times during the commute).
EV Miles
Start:175,210 Miles (281,912 Kilometers)
Current:176,402 Miles (283,830 Kilometers)
Total:1,192 Miles (1,917 Kilometers)
 
    As of 5/1/2008
Seating Capacity2 adults
Curb Weight3,175 Pounds (1,443 Kilograms)
Minus driver. Original ICE curb weight was 2250.
Tires185/60 R14 LRR
Conversion TimeAbout 2.5 months of actual work. Wasted 1.5 months at the beginning waiting for the first 2 parts dealers I tried to answer my enquiries--they never did. EV America (the 3rd dealer I tried) came through for me. Once the car was completed, I wasted an additional 4 months waiting for Zivan Company to send me a charger--never did send one. Finally canceled my order and built the homemade charger. I've since been waiting for a RussCo charger (for 1.5 months so far) from EV Parts. Hopefully this one will actually materialize.
Conversion CostLet's just say almost 3 times what I thought it would be.
Additional FeaturesI made a tach sensor out of Hall-Effect sensor and 2 south pole magnets from mouser.com (plus a bit of PVC pipe adapter). Cost less than $35.

All lights interior and exterior are LED, other than headlights. Converted the fog lights to high-intensity LEDs for use as low-current "running lights".

I upgraded the suspension with "Ground-Control" Eibach adjustable spring kit. Vehicle clearance dropped by 1.25-1.5 inches, but car handles well in spite of weight-gain, no rocking or leaning in corners.

I built/shaped my own splash pans out of plastic signboard sheets to protect engine compartment and original radiator area.

At Brian Hughes' suggestion I drilled small mounting holes in the rear brake pads' metal brackets and installed spreader springs to push pads away from rotor when not being applied, hence reducing friction. It seems to have reduced brake drag, giving me more speed for the same voltage applied.

I installed the Russco charger between the seats on rubber shock mounts, using original mounting holes for storage box (see pix).
I bought most of my parts from EV America--a dependable dealer.

Finally got the charger April 8, 2008--seven months after I first placed an order for one (a Zivan that never materialized).

code by jerry