BeforeAfter e-ProtegeInterior InstrumentationBattery PackBattery Box HeatingEMUS BMS Control UnitRear Suspension Coil Springs
OwnerJim K
LocationMontreal, Quebec Canada map
Web/EmailWebPage email image
Vehicle2000 Mazda Protege
LX Model with electric windows, mirrors, locks, sunroof. The A/C and cruise control were removed.
MotorNetgain Warp9 Series Wound DC
Dual shaft. Rear (CE) shaft is used for power steering and tach sensor.
DrivetrainStock 5 speed manual transmission with clutch
ControllerCurtis 1231C-8601
With Curtis PB-6 potbox
Batteries45 Thunder Sky LFP160, 3.20 Volt, Lithium-Ion
Battery box is partially insulated with a heating option and located in the trunk. Using an EMUS BMS made by Elektromotus (https://www.elektromotus.lt).
System Voltage144 Volts
ChargerElcon PFC 3000W
Sealed unit
Dual 120 vac / 240 vac capability
HeaterTwo 1500 watt ceramic core heaters (1 for low, 2 for high).
DC/DC ConverterIota DLS-45
InstrumentationWestberg Ammeter
Westberg Voltmeter
HP iPAQ PDA for EMUS BMS EVGUI
LED Light indicators for motor temperature warning and charging.

Stock speedometer and tachometer are functional.
Top Speed75 MPH (120 KPH)
Can attain highway speed (110+ km) but usually drive 70-90 KPH.
AccelerationDecent but less than original ICE.
Range62 Miles (99 Kilometers)
The commute from home to work is 23 kms (14.3 miles). After my daily commute, recharging back to full capacity takes 4.5-4.75 hours (120VAC - 20A circuit).
Watt Hours/Mile356 Wh/Mile
222 Wh/KM
EV Miles
Start:203,000 Miles (326,627 Kilometers)
Current:270,000 Miles (434,430 Kilometers)
Total:67,000 Miles (107,803 Kilometers)
Seating Capacity4 adults. Two adults and two children (very comfortably).
Curb Weight2,900 Pounds (1,318 Kilograms)
Stock ICE vehicle before conversion is just under 2500 lbs. Weight after conversion is 2900 lbs.
Tires195-55-15 summers on original mags
Conversion TimeStarted work in September 2008 and finished in July 2009 (10 months). Worked on it mostly part-time (weekends).
Conversion CostTotal Cost is approx. $25,000 CDN including car purchase.
Additional Features1. Added a spare tire mount using a custom bracket on top of the battery box located in the trunk.

2. Added two charge cable adaptors for 240 VAC and an extra 40 feet of length of extension cable.

3. Added a control box to house the electrical components in the front motor compartment.

4. Replaced PakTrakr BMS with EMUS BMS made by Elektromotus.

5. Added a sprocket like plate to the power steering pulley on the CE motor shaft and used stock tach sensor to re-enable RPM readings on the stock tachometer.
So far have done 67,000 kilometers of mostly daily commuting to work and back home. The range of the car was over 100 KM (62 miles) but this has decreased over time as the battery pack has aged.

I am still driving the car and it is now FOR SALE.

All serious offers will be considered, however, I prefer to sell it complete (as is) rather than dismantle it to sell individual parts.

This would make a great project car for students learning in the fields of science or automotive technology.


code by jerry