Tilt bedUnder HoodController BoardModified BedGoal was stock look.
LocationArlington, Texas United States map
Web/EmailWebPage email image
Vehicle1983 Nissan 720 Pickup
Small pickup seemed to be the best EV for me. My goal was a 60
mile range so using the estimate of 20-25 lbs of lead per mile I
needed something that could carry 1500 lbs of batteries safely.
Found this one with a seized motor in Oklahoma.
MotorNetgain Warp 9 Series Wound DC
DrivetrainStock 5 speed manual.
ControllerCurtis 1231C
***UPDATE 6/13/2009 - Curtis controller is working well. See
website pics for how heatsinks from old PCs were added to
aluminum mounting plate to help keep it cool.
***UPDATE 5/10/2009 - Zilla sold
***UPDATE 4/22/2009 - The Zilla is for sale on Ebay right now if
your interested.***
Ordered Zilla in August but couldn't wait until delivery in March so
went with the Curtis to get on the road. Not sure I want to rebuild
it around the Zilla so it may be available on Ebay when it finally
Batteries22 US Battery US145 XC, 6.00 Volt, Lead-Acid, Flooded
254 AH each. Special ordered Offset-S terminals.

***Update 9/5/2009 - Did full test of my batteries on 8/8/2009 and
everything looks great (approx. 25 charging cycles so far.) One
battery at 6.48v, two at 6.44v and the rest in between. Checked
specific gravity on all 66 cells and had four at 1.245, two at 1.265
and all the rest in between. Looks good to me!
System Voltage132 Volts
ChargerManzanita Micro PFC-20
***Update 9/5/2009 - Charger is working great now but I have one
complaint...the timer on the constant voltage stage only goes up to
about 2 hours and that is not getting my pack up to full based on
specific gravity test. I have to turn the charger off and back on to
run through another 2 hour constant voltage cycle before my pack
is full. I am looking at getting a timer for my 220v outlet that would
turn off the charger and back on in the early morning hours so the
pack would be fully charged without manual effort.

***Update 6/13/2009 - It turned out that charger had a faulty part.
Returned it to Manzanita for repair and it is working correctly now.
I had finally identified the problem to be that the constant voltage
phase of the charge was not holding volts constant. Rich at
Manzanita told me that total pack voltage should not increase
more than 4 volts from the start of the constant voltage phase.

***Update 4/22/2009 - still haven't figured it out completely but with
help from the North Texas EV club guys I'm closer. Biggest
improvement was to increase the timer from the initial setting of 15
minutes or so to about 2 hours. Still not quite there...suggestions

Chose this charger because I need to charge at work in standard
110 volt outlet. Installed 240v 30amp outlets for overnight

I still haven't figured out the right settings to bring batteries up to
full charge based on specific gravity. Could use some help from
someone using 6v flooded batteries and this charger.
Heater***Update 9/5/2009 - it's getting to be time to address this. I still
have the stock heater core in place so will look at hot water
options first. If not that then I'll pull the core and fit in a ceramic
heater element.

none yet
DC/DC Converter HWZ1-DC-DC
144V to 13.5V, 25amp
Instrumentation0-500 amp meter, 90-150 volt meter, stock 12 volt aux battery
meter. Tach sender and collar for tail shaft not installed yet.
Top Speed65 MPH (104 KPH)
***Update 6/13/2009 - Have those new tires now and have logged
over 120 miles on the highway at 60-65 mph.

Update 4/19/2009 - Still don't have new back tires but went ahead
and took it on the highway for the first time. Hummed right along at
65 in 4th gear. That should be about 3200 rpm by my calculations.
AccelerationUpdate 6/13/2009 - Acceleration is good, even getting on the
highway. My shifting is getting smoother. It took some re-learning
to let clutch out all the way before hitting accelerator (because of
relay to protect from over-revving motor).

Seems ok but I'm not merging on to the highway yet. Acceleration
in 1st is good but I can't shift smooth so usually start in 2nd.
Range50 Miles (80 Kilometers)
***Update 9/5/2009 - I have made my commute (60 miles round
trip) 11 times now and volts are consistently 133 (50% DOD) when
I get to work. I charge at 10amps until I leave and have about the
same 133 volts when I get home.

***Update 6/13/2009 - I have driven it to work twice, 30 miles each
way with 25 miles on the highway. Started with full charge 140.1
volts and when I arrived at work I had 133.5v the first trip and
133.7 the second. That's approx 48% DOD and should improve as
my batteries are broken in. I charged up at work these two days
for the return trip.

Don't know yet. I need 30 miles to get to work where I can charge
for return trip. Would be nice if I can make entire 60 mile trip with
80% DOD.
EV Miles
Start:166,962 Miles (268,641 Kilometers)
Current:174,221 Miles (280,321 Kilometers)
Total:7,259 Miles (11,679 Kilometers)
    As of 9/30/2011
Seating Capacity2 adults
Curb Weight4,080 Pounds (1,854 Kilograms)
Update 6/13/2009 - I am very happy with the weight distribution of
the batteries.

Front 1,940 (GAWR 2000)
Rear 2,140 (GAWR 2440)
Total 4,080 (GVWR 4330)
Still 250 lbs left for passengers!
(weighed 2/24/2009 - no spare tire or jack)
TiresUpdate 6/13/2009 - Went with the Kumho Solus KR21 tires in
195/75R14. I have them at max pressure (44psi) right now but it is
a little stiff but "footprint" seems to be minimal and efficiency
should be good.

Update 4/22/2009: Considering Kumho Solus KR21 tires in
185/75R14 size. Treadwear rating 640, narrower than 205 for less
surface contact, 1290 lbs max at 44psi.

205/70R14 Needs new tires before I start driving on the highway.
Conversion TimeMany, many hours. August, 2008 to February, 2009. Most fun,
rewarding project I've ever undertaken!
Conversion CostEstimated $10k including $3k for batteries. I saved all receipts but
don't think I want to add them up.
Additional Features***Update 9/5/2009 - Ice water A/C works...even in Texas! I removed the expansion valve from
the evaporator and installed plumbing (3/8" ID tubing wrapped in pipe insulation) to the back of
the truck where I have a 90 quart ice chest. I'm using a 110v, 1.1amp submersible pump
plugged into a 250watt power inverter. The A/C switch closes a relay to turn on the pump.
Results? Morning drives in August (outside temp 80 degrees) I had 54 to 59 degree air blowing
from the vents. Evening drives (outside temp 92 to 98 degrees) I still achieved 56 to 61 degree
air blowing. It's a success! Yeah, but how much ice does it take? Four 2 gallon containers...64
lbs of block ice I freeze in the garage freezer. I use plastic containers and keep 2 blocks in the
container to be used for my return trip and 2 blocks dumped into the ice chest with about 2
inches of water.

Air lift springs to lift the rear 2 inches to stock height.

Relay to open contactor and turn off controller when no load on motor (clutch depressed or shift
in neutral) to protect against over-reving motor. I'm rethinking this because shifting is not
smooth when you have to completely release the clutch before you can hit the accelerator.

Using Universal Battery UB12550 deep cycle 55AH 12 volt battery for accessories. Working well
so far. DC/DC converter only on when key is on.

code by jerry