|Owner's Other EV||1999 Saturn SL2|
|Location||Steep Falls, Maine US map|
|Vehicle||2010 Factory Five Mk4 Roadster |
Kit car, replica of a 1965 AC Cobra.
|Motor||Netgain TransWarp 11 HV Series Wound DC|
11.45" diameter, with tail shaft housing 250lbs
|Drivetrain||Direct drive, no transmission or clutch|
|Controller||NetGain Controls 360V 1400A |
Liquid cooled, Hall Effect pedal.
|Batteries||384 A123 Systems 20Ah pouch, 3.30 Volt, |
High C rate cells, 96S4P
|System Voltage||316 Volts|
|Charger||Manzanita Micro PFC 30|
wired to accept both 115V and 230V
|Heater||Heated seat cushion|
|DC/DC Converter|| |
DC/DC 110-360V input from evsource
|Instrumentation||GPS speedometer / odometer, tachometer, |
WarP Drive Interface Module, Bluetooth BMS
monitor via Android tablet
|Top Speed||106 MPH (170 KPH)|
Estimated using a 4.10 rear end
|Acceleration||Still limited to 1000 motor amps for motor |
break-in and only a 120V pack, but it is
already pulling pretty good
|Range||20 Miles (32 Kilometers)|
minimal 9 kwh pack now installed,
building up additional packs to increase
to 25 kwh
|Watt Hours/Mile||489 Wh/Mile |
First calculation shows it is Terrible!
|Seating Capacity||2 adults|
|Curb Weight||1,928 Pounds (876 Kilograms)|
Currently 1928 lbs with 120V lithium
|Tires||9" wide rims on front, 10.5" on rear, |
tires will be 245/40 front and 315/35 rear
|Conversion Time||20 months and counting|
|Conversion Cost||trying not to think about it|
|Additional Features||- No roof.|
- SoundRacer - Simulated engine sound of a Shelby V8, tied
to throttle input, high powered speakers in car nose.
- Bluetooth connected Android tablet running Torque to
create a configurable dashboard display with multiple gauges
- USB connection for laptop to configure BMS
- Terrible aerodynamics on this car! Coefficient of drag
appears to be 0.5, so range is not as good as I was hoping,
but it sure accelerates nicely!
|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
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
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
1/25/12 - Battery packs under construction. 7 packs total
at 330V nominal.
8/20/12 - 3 battery packs completed and installed. BMS,
charger, SoundRacer, wireless tablet access all installed
and working. Body has been mounted
9/11/12 - All body parts mounted. All lights and wipers
complete and working. New tires installed. Now
installing the carpeting and waiting for the State
inspector to arrive and assign a VIN number.
9/20/12 - 20 mile test drive today!
11/25/12 - Building up second set of battery packs to
bring car to 240V from 120V. Poor aerodynamics and high
rolling resistance tires are hurting the range. Looking
to make modifications for both aero and tires.
2/22/13 - Three rear batteries done to make the rear pack. Pulled motor out to change to different brushes.
3/31/13 - Front to rear wiring conduits finished, rear battery tray height modified to better fit battery packs. Starting weather tight enclosure for rear pack.
First drag race scheduled in about 10 weeks. Lots to do to get ready>