OwnerRicky Suiter
LocationGlendale, Arizona US map
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Vehicle1992 Saturn SC2
MotorAdvanced DC 4001A Series Wound DC
DrivetrainStock "Performance" 5 speed transmission (taller gears, works well for an electric motor)
ControllerCafe Electric Zilla 1K
Batteries12 Trojan 30XHS, 12.00 Volt, Lead-Acid, Flooded
I advise against using these. 4 of the 12 were replaced under warranty with strangely failed cells. After warranty another 3 have been swapped out, and they only lasted about a year.
System Voltage144 Volts
ChargerManzanita Micro PFC30
2 Hours is about all it needs!
HeaterPreheat with a $8 120vac heater. Doesn't get that cold in AZ.
DC/DC ConverterIota DLS 55
I had a 240vac version before, but it would brown out once the pack voltage went down. The 120vac version works fine and is left on continuously.
InstrumentationE-meter + Stock Speedometer and Tachometer both work.
Top Speed80 MPH (128 KPH)
It was still pulling the one time I tried it, but this lady wouldn't get out of my way.
AccelerationWant more.
Range35 Miles (56 Kilometers)
New battery range was close to 40 miles, after about a year it's got a good 15 miles in it combined freeway and city. After 15 miles voltage starts getting a bit low. Cycle life on these is not so great.

After a year I'm down to about 5 miles
Watt Hours/Mile200 Wh/Mile
Careful city driving with lots of coasting and smart timing of lights.
EV Miles
Start:162,007 Miles (260,669 Kilometers)
Current:165,000 Miles (265,485 Kilometers)
Total:2,993 Miles (4,815 Kilometers)
 
    As of 2/27/2007
Seating Capacity4, but 2 comfortably.
Curb Weight3,200 Pounds (1,454 Kilograms)
approximately
TiresGoodyear Integrity ("fuel efficient") 185/65/15. I Think they're LRR but have no numbers to prove it. This is the OEM 2004+ Prius tire.
Conversion TimeLong story, 4 years from engine pulled to working EV. Motor was installed in 2001, the rest of the work happened in summmer of 2005. Painted in the summer of 2006. Will be getting a battery retrofit along with some other improvements summer 2007.
Conversion Cost~ $9,000
Additional FeaturesWater cooled Zilla is great for Arizona summers.
Fast recharges with the PFC30 charger
Battery boxes in trunk sit below floor. Once I make lids I will have the full trunk available.
"Performance" version of the transmission has higher gear ratio's so unlike other conversions I actually use 3rd in the city and 4th on the highway with the motor turning close to optimal.
The car still has the power steering rack in it, but unassisted it is really not all that bad. I attribute this to the car being relatively light up front. .31 Coefficient of Drag, pretty good for a 15 year old car.

code by jerry