BeforeAftere-ProtegePakTrakr Lithium Batteries
OwnerJim Karamalis
LocationOttawa, Ontario 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
Batteries40 Thunder Sky LFP160, 3.20 Volt, Lithium-Ion
Battery box is partially insulated and located in the trunk. Cell balancers (volt blocher) are used to shunt excess energy while charging for equalization.
System Voltage128 Volts
Charger 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
Pak Trakr 800 (for Lithium)
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:126,680 Miles (203,828 Kilometers)
Current:128,561 Miles (206,854 Kilometers)
Total:1,881 Miles (3,026 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
185-65-14 winters on steel rims
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. $26,000 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 home made noise filter for the PakTrakr display.

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

So far have done over 3000 kilometers of mostly daily commuting to work and back home. The range of the car is 100 KM (62 miles) but since I do not want to discharge more than 80%, I limit my longer trips to about 80 kilometers. This will extend the battery pack's cycle life. I am having a great time driving the car and already dreaming of the next conversion I'd like to do.

:-)

code by jerry