Most of the components...Free Tax!!CarPuter InterfaceNew motor/gearbox ready to install...Motor mount brackets tack-welded...My Current EV...The New ClutchEV Part IIThe End of it All
OwnerMartin Winlow
Owner's Other EVs2008 Vectrix VX-1
Sebring SX Kit Car
LocationMuch Hadham, England United Kingdom map
Web/EmailWebPage email image
Vehicle2001 Daihatsu HiJet (aka Piaggio Porter)
Japanese Micro-van, built in Italy
MotorNetgain Impulse 9 Series Wound DC
(www.go-ev.com - NetGain Motors Inc)

Continuous 30HP, peak 100HP
Max RPM 5500'ish.
DrivetrainStock 5-speed manual transmission to rear
differential. Ratios (inc 4.44 diff) 1st=16.7,
2nd=9.1,
3rd=6.1, 4th=4.44, 5h=3.7.

Tyres: - 155/68 R 12 C

UPDATE - 17/7/09 - Despite my reservations,
going clutch-less is ok'ish. Just a few seconds
delay whilst the gearbox cogs sort themselves
out when shifting but I am planning to put the
clutch back in soon, simply because it makes
the system more flexible when negotiating
junctions etc. It will aslo give the van much
better acceleration as I'll be able to change
gear much more quickly.

UPDATE - 04Jul10. Clutch now re-instated
with a home made flywheel. It is SO much
easier to drive!!!
0-60 acceleration HALVED!
ControllerBelktronix 800A
(www.belktronix.com)
Complete system including battery monitors
(over &
under voltage only - no voltage display or
logging -
see later for that - one per cell - 38 in my
case) and
charge balancers, 2.4kW charger/DC-DC
converter
(50A @ 13.5V), 800A max controller, opto
'pot-box'
(throttle control) and associated gubbins
including
main contactor.
Batteries38 Thunder Sky LFP160, 3.20 Volt, Lithium-Ion
(www.thunder-sky.com)

Nominal Capacity - 160AH
Operating Voltage - 2.5V to 4.25V
Weight - 5.6kg
Dimensions - 182W x 279H x 71D (mm)
Pack Weight - 215kg
System Voltage120 Volts
ChargerBelktronix (See above)
Is in same box as DC/DC converter. 2.4kw
output. (www.belktronix.com) Full range charge
in 8 hours.
HeaterDiesel Webasto water heater through stock
blower unit.
(Not yet fitted - still! 27Oct10).
DC/DC ConverterBelktronix (See above)
50A @13.5V
InstrumentationCarPuter running Windows Xp with
CentraFuse-V2 incorporating SatNav, USB FM
radio tuner, MP3 player, free mobile, home
brew VisualBasic based BMS monitoring,
warning and data logging
program. System status texting and polling
to/from mobile phone. Plus stock speedo etc.
Top Speed70 MPH (112 KPH)
On the flat with no wind.
AccelerationQuite peppy starting from 0 in 2nd gear and
frankly rather scary in first! Drops off after
about 30mph as the wind resistance builds up.
Overall, better than stock at low speeds but
similar at higher speeds.
Range70 Miles (112 Kilometers)
Not tested for real yet but should be around 60
miles at 50mph, half that at 70mph - if it goes
that fast and about 150 miles at 10mph.
Watt Hours/Mile350 Wh/Mile
Definitely something best suited to the
empirical method of divining but due to the
vans poor Cd (little better than a house brick),
not good. In winter, using the mains-powered
battery warmer muddles things
greatly but it is part of the function of the EV
so I guess it should be included.

Update - 280709 - It draws about 140
(battery) amps at 50MPH (120V pack). The
Whr/mile figure (above) is based on the
calulation of volts x amps at the relevant
speed (in mph) divided by that speed (see
tabled power consumption lower down).
EV Miles
Start:51,948 Miles (83,584 Kilometers)
Current:65,681 Miles (105,680 Kilometers)
Total:13,733 Miles (22,096 Kilometers)
Seating Capacity2 adults
Curb Weight2,300 Pounds (1,045 Kilograms)
...before conversion.

- ICE 1300cc alloy engine 107Kg
- fuel tank 11kg
- full tank of petrol 23kg
- cooling system - 11kg
- Bits and Bobs - 7kg
- exhaust/cat 18kg
Total = 177kg

+ motor 57kg
+ batteries and box 240kg
+ electronics 20kg
Total = 317kg

Result = 140kg increase
Post conversion (calculated) = 2640lbs
(1200kg).
Update 01Oct10 - Pu the van on a weigh
bridge at it came in at 1008kg with no load.
Tires155R12/88
Conversion TimeTo plan, research and acquire all the bits...
about 18
months.

To instal everything bar heater, about 10 x 8
hour days. However, I don't know how long
it's going to take to iron out the bugs or
'finish' it. Will it ever be 'finished'?
Conversion CostDon't ask...
Motor - £1200 (imported direct from US)
Combined and matched control electronics,
charger-cum-DC/DC converter, system
integrator and battery balancing system -
£1440 Carputer & battery monitoring
hardware - £400 ... but the good news is
that the electronics should last for 1000k (yes,
1 with 6 zeros after it) miles so they can be
moved from one donor to another... that's the
theory at least!

At 50MPH it costs around 1p per mile in
electric which means each time I use the van
to do my usual commute, I save around £5 -
no servicing costs and no tax and no MOT
(something to do with milk floats).
Additional FeaturesBrakes:- No ICE = no vacuum source for the brake booster. Ergo,
the vacuum must be obtained elsewhere. I started with a cobbled
together used vacuum pump from a Volvo S40 but it never worked
well and the switch kept failing so I bought a Cibi (MES DEA) 70/6E
purpose-designed pump which works beautifully, practically silent
and is simplicity itself to fit. The downside is the price. I was
quoted £320 from CIBI (UK) and £450 from another UK source but
in
the end bought it from the US, delivered and VAT/duty paid for
£240.
From Switzerland to the US and back again and at half the price I
can
buy it for here in the EU - Bonkers!

27Apr11 - Planning a photovoltaic array installation for the garage
roof to offset the electricity the van uses. If it were big enough, it
could power the van completely. As it is, I can only get a 1kW
(peak) array up there comfortably. It would be nice to have a big
array but it is still to exy and I have limited room. One day it will be
possible perhaps even compulsory - every new build must have a
PV array capable of generating x% of its anticipated energy use? -
then it would be easy-peasy, or 'EV-PV' as you might say.


Road Tax - Getting the converted van taxed (for non-UK readers
this is the vehicle excise licence - levied by the G'ment and helps
pay to maintain roads etc - well, given that 1 in every 3 pounds
spent
by the UK G'ment goes on the welfare state, it actually helps pay for
that). This is free in the UK for electric vehicles but first you have to
battle G'ment bureaucracy to get it signed off as 'tax class =
electric'.

I had to take the van to my 'Local Office' of the DVLA at
Borehamwood for an inspection. Took 10 mins (30 mins waiting -
of course, despite pre-booked appointment. There is very little
helpful info on the DVLA's web site about this.

An electric blanket installed with the batteries keeps the battery
pack at a warm and toasty 22 deg C whatever the temperature
outside.

In a bid to minimize pack imbalance I have wired the controller
power to come from the whole pack via a mains PSU which appears
to work happily at 120V DC. Ditto the heater.

Electric 'Fuel' Economy (Wh/mile which includes all standby electric
costs - warming batteries, carputer - charger inefficiancies and
excludes savings from charging at work)...

Date ........ kWh ...... miles .... wH/ ........ Fuel .... £
................................ done ..... mile ......... p/l ... saved
22Aug09 .. 44620 ... 52352
31Aug09 .. 44808 ... 52520 ..... 303 ....... 106 ...... 68
18Oct09 .. 45030 ... 53008 ..... 455 ....... 106 ...... 58
15Nov09 .. 45174 ... 53512 ..... 486 ....... 109 ...... 36
29Nov09 .. 45296 ... 53532 ..... 535 ....... 109 ...... 27
16Dec09 .. 45421 ... 53885 ..... 353 ....... 108 ...... 43
29Dec09 .. 45518 ... 54129 ..... 398 ....... 108 ...... 38
24Jan10 .. 45506 ... 54704 ..... 490 ....... 112 ...... 40
06Feb10 .. 45671 ... 55039 ..... 493 ....... 112 ...... 43
08Mar10 .. 45867 ... 55649 ..... 555 ....... 114 ...... 31
27Mar10 .. 46097 ... 55868 ..... 600 ....... 116 ...... 24
06Apr10 .. 46206 ... 56105 ..... 460 ....... 120 ...... 29
19May10 .. 46465 ... 56669 ..... 459 ....... 122 ...... 70
24Jun10 .. 46657 ... 57169 ..... 384 ....... 120 ...... 62
05Jul10 .. 46766 ... 57414 ..... 444 ....... 118 ...... 29
04Aug10 .. 47025 ... 58012 ..... 433 ....... 118 ...... 72
15Aug10 .. 47143 .. 58282 ..... 437 ....... 117 ...... 32
15Sep10 .. 47332 ... 58731 ..... 449 ....... 115 ...... 53
18Oct10 .. 47597 ... 59298 ..... 467 ....... 118 ....... 68
20Nov10 .. 48036 ... 60213 ..... 480 ....... 118 ....... 109
14Dec10 .. 48322 ... 60748 ..... 721 ....... 121 ....... 65
27Jan11 .. 48760 ... 61594 ..... 438 ....... 128 ....... 111
12Feb11 .. 48974 ... 61996 ..... 532 ...... 128 ....... 52
12Mar11 .. 49294 ... 62617 ..... 515 ...... 132 ....... 83
09Apr11 .. 49587 ... 63232 ..... 476 ...... 132 ....... 80
13May11 .. 49822 ... 63011 ..... 470 ...... 137 ....... 68
14Jun11 .. 50074 ... 64311 ..... 435 ...... 136 ....... 79
30Jul11 .. 50597 ... 65551 ..... 421 ...... 136 ....... 170
08Aug11 .. 50647 ... 65681 ..... 384 ...... 135 ....... 17

Total saving in petrol over 2 years & 13,700 miles = UK£1,662

And that's the last entry I'm afraid as my van was written off in
an accident on the 7th August. I will be salvaging the electric drive
which appears undamaged and progressing to EV Part II (see above
kit car photo) next year. OK - 2013, then. No, 2014! Nearly the end
of 2016 and it still isn't done. I have been distracted by retiring,
divorcing, starting a business (EVBitz.uk) and planning a move to a
remote island off the west coast of Scotland. Seems a reasonable
bunch of excuses to me!

I'm also looking for a used HiJet 4WD to convert - using the old
drive train (as it is all ready to 'drop in'). If you have one going
spare, please let me know.


code by jerry