OwnerRichard & Fiona Blinco
LocationMarino, South Australia Australia map
Email email image
Vehicle1983 Suzuki SS80V
Two seat, lightweight panel van, aka 'Red Rocket 1'. Bought as a
partially completed project. Formerly three cylinder 800cc ICE.
MotorD&D Motor Systems, Inc. ES-32A-50 Separately Excited DC
Originally had ES 10E-33 motor that came with car. Not up to the
job but living with it for the moment. Replaced with ES-32A-50 May
2013.
Replaced with Motenergy MR1114 when controller failed.
DrivetrainOriginal 4 speed gearbox, no clutch. Custom built adapter plate
with
a Lovejoy coupling.
ControllerSevcon PowerPak
Controller failed. Decided to go with different controller/motor
configuration. Sevcon Gen 4 size 4 with Motenergy PMAC motor.

Has been a nightmare to get this setup working. Have the dvt
software and CAN interface but getting adequate info about the
settings for this controller has been very difficult.
Car is back on the road as of Jan 2015 but drivability is not great at
the moment.
Mainly looking at four parameters in the software. Very much trial
and error at the moment.
Batteries24 CALB/Skyenergy 130ah, 3.40 Volt, Lithium Iron Phosphate
System Voltage72 Volts
Charger TC Charger
HeaterTwo 12V travel hair dryers for demisting. Mounted directly into vent
outlets under dash. Rocker switch to activate.
DC/DC ConverterSevcon
InstrumentationSevcon ClearView display/interface.
Top Speed45 MPH (72 KPH)
Range38 Miles (61 Kilometers)
Lithium upgrade delivered significant boost. 60km to 80% DOD
Watt Hours/Mile180 Wh/Mile
Seating Capacity2 adults
Curb Weight1,433 Pounds (651 Kilograms)
Lost 70kg with upgrade to Lithium Ion
Conversion TimeLots.
Conversion CostInitially $6000 - Car with motor, electrics, batteries and housing
complete.
Other costs - Engineer's report $500, repairs to charger $400, lots
of other misc items maybe $1000. Second hand and surplus
materials/parts sourced by my brother.

Lithium battery upgrade $6000

New second hand motor from NZ, $800 including shipping.

Conversion originally started by Derek Clarke who set up the electrics, motor and battery
housing. Bought the car in a drivable state but requiring more work to get it past a DETI
inspection.

Had some issues with the motor/gearbox alignment so we replaced existing motor adapter plate
and coupling with a new aluminium adapter plate designed and fabricated by my brother Ian. He
also fitted a Lovejoy coupling. Got rid of the clutch as part of this overhaul.

Repairs to the gearbox gear selector arm, replaced drive shaft seals. New (second hand) seats,
seat belts, roof lining, battery ventilation system, new aluminium battery housing lid,
polyurethane(?) sheeting under car, installed PakTraker system, motor temperature sensor, some
minor rust repairs and a bunch of other minor but fiddly bits!

July - October 2012 Lithium Ion upgrade. - With much help from brother Ian, pulled out previous
battery mounting and engineered a very tidy mounting system, aluminium and stainless. Re-
routed HV cables, put all the electronics into an aluminium box mounted on the gearbox. New
contractor/coil, Cycle Analyst, battery charger mounted in the front, power
connection fitted in previous fuel door. Lots of issues between controller and contactor slowly
worked through. Reversing now through controller, much smoother than reverse gear.
Regenerative braking set up mainly to assist the pitiful non power assisted original brakes -
hydraulic pressure sensor on brake line feeds info to controller for proportional regen.

New rear shockers. Getting the springs at the front re-set so the car sits at the proper height.

Feb - April 2012. Motor finally gave up. Burnt field windings from working too hard. Had it
rewound but by chance connected with Thomas Everth (WebPage who was
considering selling his more powerful model of D&D motor after having issues with controllers
for sep ex motors. Eventually got round to buying his motor, has arrived in
Adelaide and should have it in next weekend. Very much hoping that this will solve overheating
problems, give a bit more power output and longevity.

May 2013 - ES-32A-50 motor arrived from NZ. Had to cut a key in the drive shaft, swapped the
rear bearing. Installed in a few hours. With some reprogramming of controller motor works much
better than previous, temp stays withing operating range. Much happier!

Quick survey of the car shows that we have redesigned and/or replaced all of the original
conversion except for the Sevcon controller and DC converter. I suppose most of us are not
doing this with the economics or the process in mind.

Controller died Sep 2013. Not fixable and given all the issues with motor over heating have
decided to try a new motor controller combination.

New Sevcon Gen 4 and motenergy combo working but different torque characteristics to
previous setup make for interesting driving. Motor theoretically has more power but seemingly
not so much at take off. Robert Doig has similar EV setup but slightly bigger motor and seems to
get by. Would probably be ok with clutch, drive like a regular manual but got rid of this with the
previous setup!!! Considering options such as putting 2-speed auto in and bypassing torque
converter.


April 2016- Gearbox sprang a big leak while out driving and tweaking the controller. Given the
amount of time, effort and money spent so far and other issues, wondering where to go from
here.

June 2016 - Have bought a 2013 iMiev. Great car with excellent range and drivability around the
city. I think the days of tinkering with conversions are at an end!

code by jerry