Under the hoodThe rear endE-Meter installationRefueling...Motor bolted to gear boxAC distribution box
OwnerThomas Everth
LocationCoromandel, Coromandel New Zealand map
Email email image
Vehicle1990 Toyota Starlet
conversion for local driving (90% of my rides) in the Coromandel township.
MotorD&D Motor Systems, Inc. ES-32A-50 Separately Excited DC
Got this through Thuderstruck WebPage in California.
DrivetrainManual gearbox, front drive, 5 gears
ControllerSevcon PowerpaK
DC Controller with regenerative braking, throttle and brake potentiometer and electric reverse/forward switch.
Purchased through Thuderstruck WebPage in California.

June 2009: The controller blew up after about 9 month in service when driving up a light incline and pulling about 240Amps. No external problems visible and the controller passed its self test (green light) but the controller is not starting. When removed from the car I can hear lose debris sloshing around inside, pointing to an internal explosion of some kind.
Sevcon, the maker of the controller, is denying warranty cover. :-(
While this controller worked well as long as it did, the fact that they are not honoring their warranty is a shock. Perhaps this is just because I am in New Zealand and to far away from the UK to cause them legal trouble. Who knows. But I do not think that this is a smart business move!
Batteries6 Trojan T-1275, 12.00 Volt, Lead-Acid, Flooded
150 AH deep cycle 12 Volt. Pack weight about 222Kg

System Voltage72 Volts
Charger Wellforces, Auckland
Bought 3 chargers at 24V 12.5A for about $150 each. Friendly company. Made in China I believe but looking good.
Site: WebPage
HeaterHat and mittens...!
DC/DC Converter Wellforces, Auckland
DC/DC converter 72 to 96V in, 12V 30A max output used to top up small 12V auxiliary battery.
Site: WebPage
InstrumentationE-Meter from Able Solar, Auckland
Top Speed50 MPH (80 KPH)
Reached 80 Km/hr on last test drive in 4th gear.
AccelerationJust like before to 60Km/Hr then a bit slower.
Range20 Miles (32 Kilometers)
First test of full battery discharge was 20 miles. But on the same drive I also repeatedly went for max speed and had a few climbs. So actual range at 35MPH on flat land should be a lot better.
Watt Hours/Mile400 Wh/Mile
Used 90KWhr AC charging for 400Km. That is 0.24 KWhr / Km or 24KWhr per 100Km or at NZ power prices of about NZ$0.16/KWhr that is NZ$3.84 / 100Km of driving.
EV Miles
Current:3,800 Miles (6,114 Kilometers)
 
    As of 11/2/2010
Seating Capacity4 adults
Curb Weight2,028 Pounds (921 Kilograms)
After conversion = 920Kg total
Front Axle = 530Kg
Rear Axle = 390Kg

Before conversion = 840KG

Weight gain = 80Kg


Tires4
Conversion TimeMany days so far....
Conversion CostAbout NZ$11,000 including the base car, a $2100 Trademe purchase.
On Fuel savings: 100Km in the base car at 6L/100Km at $2 per Liter = $12 for fuel. Now: About 20Kwhr charging per 100Km at $0.16/KWhr = $3.20 or a saving of $8.80 per 100Km or 75%.
At 15,000 Km / year the savings are $1320, a return on my investment of well over 10%!
Additional FeaturesRegen braking, 3 batteries under hood, three in battery well sunken where the spare wheel once was. Will carry no spare wheel.
Had more extended test voyage today! Works like a charm!
Have seen up to 400Amps on acceleration. Got up to 80Km/hr.
Made it back up our steep drive (15Deg) easily.
Great fun!
Regenerative braking is great just with throttle in idle.

I fitted a relay to the brake light that switches the controllers regenerative braking mode to a high setting. Ideal! With the foot of the accelerator the car slows like a petrol car with the engine braking, and when the brake light comes on with a lightly depressed pedal the car slows a lot better. Great for rolling down hills.




code by jerry