OwnerBrian Pawlak
LocationMesa, Arizona US map
Vehicle1992 Ford Escort
"SOLD" Originally donated to UCI in Irvine California, and converted to a hybrid as an engineering project. See WebPage
MotorAdvanced DC FB 4001 Series Wound DC
ADC 9" motor with the shaft on both ends. I have my speed sensor mounted on the back shaft to drive the Tachometer.
DrivetrainOriginal 5 speed manual with a ceramic clutch.
ControllerCafe Electric Z1K-LV
1000 Amp Zilla Controller. Hairball interface has trouble codes and 2nd "Valet mode" settings for Amps, Volts etc. I am using the "Valet mode" as a second set of parameters to get better range when needed.
Batteries15 Trojan T-875, 8.00 Volt, Lead-Acid, Flooded
I have automotive style posts.
System Voltage120 Volts
ChargerLester Model 07740
220V AC input - output is usually 26 AMPS Needs about 6 hours to charge from 80% discharge. I still have the onboard Zivan for charging away from home, but it is 120 AC input and only charges at 12 AMPS max.
HeaterElectric ceramic element in place of the original heater core, just in case I need to defrost the windshield. (I'm near Phoenix AZ).
DC/DC ConverterZivan NG1
120VDC to 12VDC
InstrumentationVoltmeter, Ammeter, Speedometer, Tachometer, Curtis State of Charge Meter, Battery charger indicator light for onboard charger.
Top Speed75 MPH (120 KPH)
I have had it on the freeway in 4th gear at 75 MPH. Range decreases dramatically at freeway speeds.
Acceleration0-45 in 36 seconds, at 200 AMPS MAX measured at the motor.
Range50 Miles (80 Kilometers)
50 miles is with the driver only, (150 lbs), at or below 45 MPH and below 200 amps while cruising and accelerating. I also am using the "valet mode" to assure less than 350 amp draw by the motor. 30-40 miles is usual with more passengers and more agressive driving. This will take the batteries to 80% discharge.
EV Miles
Start:662 Miles (1,065 Kilometers)
Current:12,650 Miles (20,353 Kilometers)
Total:11,988 Miles (19,288 Kilometers)
Seating Capacity5 adults
Curb Weight3,460 Pounds (1,572 Kilograms)
This is now an actual weight. The front and rear axel weight is withn 10 pounds.
TiresP185 60/R14 Riken Raptor- Kept at about 42 PSI
Conversion TimeElapsed time was about 1.5 years. I worked on it some days after work for a few hrs and on most weekends. About 4 months with no progress either waiting for parts or just me being lazy. I also had to replace some of the interior, and most of the wiring harness in the engine compartment needed to be replaced or repaired.
Conversion CostEst between 12-15K.
Additional FeaturesIt has a full front to back "belly pan". Originally I did this to improve aerodynamics, but it also keeps the engine compartment clean, and protects the battery charger that is mounted below the rear seat. The radio antenna and roof rack were removed and the roof smoothed for aerodynamics. The radio antenna was left inside the front pillar near the windshield - it works good.
I did drive to and from work daily starting 6-24-08, 5 days per week. It is 48 miles round trip. this lasted for about 6 weeks when the batteries failed due to using the onboard charger that was not quite fully charging the batteries. I found that you do need a good strong charger, (220 V high AMP), to keep your batteries happy if you discharge them to 80% often. My wife now uses the car daily to go to work and drop off the kids etc. It generally sees 16 to 30 miles a day, usually not more than 50% discharge. The 220 Volt Lester charger can fully charge the batteries from a 20 mile trip in about 3 hours. Fully ballancing takes longer at very low amps.

code by jerry