Sunshine and Green Power SourceMachined Flywheel on Azure AC24LS MotorTransmission, Rear Suspension and Motor Azure Dynamics DMOC Controller
OwnerJack Marshall
LocationLos Gatos, California US map
Vehicle1974 Porsche 914
MotorAzure Dynamics/Solectria AC24LS 3-Phase AC
DrivetrainI used the stock clutch and five speed transaxle, but I had problems with vibrations around 4500 rpm. So I had the flywheel machined down from its original 17 lbs. to about 11 lbs., shortened the motor shaft and spacer ring by about 5/8" and had everything really well balanced. This completely eliminated the problems. (Many thanks to Mike Brown and Shari Prange of Electro Automotive!)
ControllerAzure Dynamics/Solectria DMOC445
Batteries18 US Battery 8VGC HC - XC, 8.00 Volt, Lead-Acid, Flooded
System Voltage144 Volts
ChargerElcon PFC 1500
HeaterA pair of travel-size hair dryers connected into the original heating ducts. They're switched using a beefy DC relay controlled by the original heater switch on the floor. I hooked them up in parallel and set their switches to "low" and this works fine from the 144V main battery.
DC/DC ConverterElcon TDC 144 14 EGC
InstrumentationAmmeter (+/- 200A), SOC Gauge, 12V system voltmeter. The original tachometer, alternator light and oil pressure light are driven from the Azure Dynamics controller.
Top Speed70 MPH (112 KPH)
This was on flat road with nearly a full charge.
AccelerationThe acceleration isn't anything to write home about - zero to sixty is over 20 seconds.
Range53 Miles (85 Kilometers)
This is typical range at 35 to 45 mph with some red lights and only moderate accelerations. I try to drive fewer than 45 miles on a charge. Any farther and the performance really suffers.
Watt Hours/Mile300 Wh/Mile
This is the typical wall socket to odometer efficiency at 35 to 45 mph. It's also a strong function of driving style and can be as low as 285 Whr/mi driving for economy or as high as 450 Whr/mi driving for fun.
EV Miles
Start:91,234 Miles (146,795 Kilometers)
Current:98,240 Miles (158,068 Kilometers)
Total:7,006 Miles (11,272 Kilometers)
 
    As of 1/14/2013
Seating CapacityTwo adults or driver plus groceries.
Curb Weight3,000 Pounds (1,363 Kilograms)
Preconversion curb weight was 2100 lbs. and 3000 lbs is a best guess. I will update this when I reweigh the vehicle.
TiresKumho Solus HP4's at max pressure -- 44 psi.
Conversion TimeTotal duration 2 1/2 years -- actually about 1 1/2 years of weekends, and then another year of tweaking.
Conversion CostAbout $18,500 plus the cost of some transmission, steering and suspension repairs.
Additional Features* Modified flywheel (see "Drivetrain" above).
* Electric windshield washer pump (from a 911) in place of the original spare tire pressurized washer.
* New hood shocks in front and rear from Camp 914.
* AC line powered 12V power supply to operate battery box fans during charging.
I used the Electro Automotive AC VoltsPorsche kit and tried not to use anything too modern other than the marvelous Azure Dynamics controller. Sunshine still has that sweet 1970's look and feel.

Milestones:
11 April 2010 - completed in time for the 40th Earth Day
13 June 2011 - passed the "1000 EV Miles" mark
3 March 2012 - 5000 EV Miles
7 May 2012 - 10,000 EV Kilometers

code by jerry