base frameMotor controller and throttle sensorFactory Five Mk4 RoadsterFirst motor mount startedBrakes n YokeFront motor mountDashboardDrivetrain installedCustom Driveline
OwnerWayne Krauth
Owner's Other EV1999 Saturn SL2
LocationSteep Falls, Maine US map
Email email image
Vehicle2010 Factory Five Mk4 Roadster
Kit car, replica of a 65 Cobra.
MotorNetgain TransWarp 11 HV Series Wound DC
11.45" diameter, 230lbs, 460 ft-lbs @ 1400A
DrivetrainDirect drive, no transmission or clutch
ControllerNetGain Controls 360V 1400A
Liquid cooled, Hall Effect pedal.
Batteries400 A123 Systems 20Ah pouch, 3.30 Volt,
High C rate pouch cells, 4P100S configuration.
System Voltage330 Volts
ChargerManzanita Micro PFC 30
HeaterHeated seat cushion
DC/DC Converter
DC-DC installed for 72V system, using 4 x 16Ah Headway cells in series to replace the 12V car battery.
InstrumentationGPS speedometer / odometer
Top Speed103 MPH (165 KPH)
Estimated using a 4.10 rear end
Accelerationshould be good
Range100 Miles (160 Kilometers)
25.9Kwh pack
EV Miles
Current:1 Miles (2 Kilometers)
Seating Capacity2 adults
Curb Weight2,000 Pounds (909 Kilograms)
estimated

currently about 1600 lbs with 72V pack
Tires9" wide rims on front, 10.5" on rear, tires will be 255/40 front and 315/35 rear
Conversion Time12 months and counting
Conversion Costtrying not to think about it
Additional Features- No roof.
- Simulated engine sound of a Shelby V8, tied to throttle input, high powered speakers in car nose.
This is a new EV build from scratch, not a conversion.

Construction started 12/31/10.

1/21/11 - Designing and fabricating the motor mounts. Next up, install the 8.8" rear end and figure out the drive shaft length.

3/3/11 - Motor installed, now assembling rear end.

3/20/11 - Third motor mount completed, rear end temporarily installed to measure for drive shaft length. Brake pedal and pistons installed. Accelerator pedal installed. Steering installed. Started installing aluminum panels...


4/5/11 - Custom length drive shaft on order, front brake lines installed, fuse panel and main wiring harness, dashboard harness in place. The passenger foot box aluminum is riveted in, and a few other pieces. The rear battery box frame has been built and installed.

4/23/11 - Drive shaft in, front brake lines in, wiring harnesses laid out, dashboard covering glued on and many gauges, switches and indicators mounted. Dash wiring under way.

6/14/11 - Dash wiring mostly completed and working, line lock installed, controller shelf fabricated and mounted, controller installed and it's wiring is started. Throttle position sensor mounted and is working good mechanically. Rear end 80% assembled and almost ready to install. Front battery tray has been fabricated and welded in.

7/12/11 - Rear end installed with calipers and rotors, started on emergency brake. Motor controller now powered up with 12V, throttle pedal works smoothly from 0-100% according to the dashboard display for the motor controller. A set of 5 contactors are installed, 2 for forward, 2 for reverse, and the main. Now wiring contactor controls. 12V direct to the motor now spins the rear wheels. :-)

Liquid coolant reservoir and pump have been mounted, still need to mount the radiator, wire the fans, fabricate something to mount a coolant temperature sensor, and add tubing to complete the motor controller cooling system.

7/22/11 - Rear brake lines installed, emergency brake assembled, installed and adjusted. Added brake fluid last night, now looking for any additional leaks. Rear tire rims mounted temporarily to make sure the brake and e-brake lines are not rubbing against them.

Two 12V lead acid batteries are temporarily in place to provide a minimal traction pack to the motor controller for testing. Contactor controls are now wired and working when manually powered, but not with the full system activated. currently troubleshooting.

9/21/11 - Finished the brakes, emergency brake, and rear end installation. Ran 12 hours at 12v on the motor to finish seating the brushes. Built framework to support the radiator that cools the motor controller. Installed the liquid pump, tubing, fans and wiring for the radiator. Added more trunk aluminum and passenger side cockpit aluminum. Mounted a stereo in the dashboard.

Increased traction pack to 72V (6 x 12V lead acid) for low voltage drive testing and to run the car until I can get a lithium pack together. The 72V pack will make about 50 hp in this car.

Installed 4 borrowed tires (thanks Dane!) for temporary use until the car becomes road ready.

9/27/11 - First test drive!!! Minimally equipped to be driven, no body, no lights, lots of stuff half-done, but it runs!

1/25/12 - Battery packs under construction. 7 packs total at 330V nominal.

code by jerry