Last Updated: 09/27/09
EV Technical Files

Citicar/Comutacar Bumper Retrofit
A simple and attractive solution to the chronic rotting bumper issue on Citicars and Comutacars

Auburn Controller Info

Here is what is all the info I have on Auburn Kodiak controllers.

Auburn Notes.jpg
Auburn Notes2.jpg
Auburn Circuit.jpg
Auburn Harness Wiring Table.htm
Auburn Scientific PWC600 Manual (pdf)
Auburn Scientific C600 Manual (pdf)

MR2 Power Steering Control

John Grigg has done a wonderful job of workgin out how to interface with the Toyota control circuits to make the MR2 power steering pump more EV freindly.

Conversion circuit to interface a conventional 0-5k ohm potbox with a Taylor-Dunn golf-cart controller.  The Taylor-Dunn controller uses a 6-10Vdc control circuit as an input.

Conversion Circuit

This is in Adobe Acrobat format, if you need a viewer you can download a free one here. 

E-Meter Manual

The new owners of Cruising Equipment seemed to have removed the manual from their website, but here is a copy if anyone needs it.
e-mtrpdf.pdf 2Mb PDF file.
It is in Adobe Acrobat format, if you need a viewer you can download a free one here. 

Controller Designs

1.  This is a schematic for a simple ebike-size controller (24v, 50 amps) that Lee Hart reverse-engineered.

28K PDF file.

2.  This is a schematic for a controller courtesy of Rod Hower, intended for 24-48V input and 200-400 amps depending on how much silicon you throw at it.

71K PDF file.

3.  Here is a complete Motorola controller design courtesy of Philippe Borges.


Helpful Electronics

Rod Hower submitted:  For those working on multiple I/O interface with optical isolation, check out QT opto ( H11ADB. I don't know if it is on their website, but this part was
originally developed for an application here at Ametek.  We used it on an isolated analog speed control input that was compensated for temperature etc.  Anyhow, this would work well for xmit & rcv and is the most space conscious part I've seen.

H11ADB6X 94K PDF File.

"Bad Boy" Charger

Tom Martin created a simple boosted bad boy charger for his 144 volt EV.

With grateful appreciation to all those who helped me with this.  I would like to share with everyone my version of the Bad Boy charger.  I know there are those who feel this is not effective, or not safe or not practical, or not something.  Well I am here to tell ya that after a lot of errors, far to many shocks with bad language attached and even more popped circuit breakers I got to the pay-off.   I found a way to make it work as the stories have said it would.  There is in my picture a light dimmer which I cannot attest to because I put mine in a different and wrong place "twice".  Yep, fried both of 'em.  The first one popped; and the second melted.  The phase of the AC is important to the final output.  If the AC voltage is lower than the input then reverse the leads on the output side of the transformer.  The thing won't pop even if the phase is wrong, the voltage will just be reduced by the value of the transformer.  Trust me!  I fought with this thing for four days.  I got bit so many times, anyway this does work.  This setup seems to work rather quickly, I put it on my 144v pack and the voltage went from 150 to 177 in about an hour.  I put an amp meter in the line and it showed never more than a 15 amp draw.  I tried using a long extension cord and it did reduce the current and the rate of charge.  I can tell everyone that if you build one, a very important thing to do the first time is to use wire that is capable of dealing with the loads, I started with extension cord wire, "Don't do that" it gets really hot.  I know!  A store bought battery charger costs over 900 bucks, I don't know about the rest of ya but I had to have a more affordable method.  This works and seems to work well.  I will run my pack down over the next three or four days and then I will see just what the reality is.

"Bonn" Charger

Lee Hart's circuit and instuctions for a simple charger for 96 to 132 Volt EVs.

Ben Fratto's Bad-Boy Charger

Ben Fratto's Bad-Boy for 156 Volt EVs.

EV Weight and Balance Help

1.  This is an extract from an excellent but out of print book, "EV Engineering Guidebook: Electric Vehicle Conversions for the 1980's", by Paul R. Shipps, complete instructions on how to calculate the weight and balance of a potential EV conversion.


2.  David Brandt has created an excellent balance worksheet in Excel.


Motor Specifications and Performance Data (these are older motors, but sometimes still available.  This data from EV Engineering Guidebook.)

Physical Dimensions 7544D Series Motor
Performance Curve

General Electric
Basic specs 5BT1346B50 Series Motor
General Electric Physical Dimensions
General Electric Performance Curve

Physical Dimensions MTC Series Motor
Performance Curve
On 72 volts
On 96 volts
With Field Diversion

Power Brake Vacuum Pumps

Here is a great page with lots of info on the GM 12 volt vacuum pumps and how to install them.  The page was written for RVs but it applies to EVs as well.  (thanks to Andrew Letton for pointing it out.)

Webpage by Mike Chancey