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Electric Vehicles, EV, hybrid, hybrid vehicles, clean energy, green power, solar power, wind power, Bloombox, home based power, fuel cell, wind generator, incentives, rebates, government, government policy

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Location: Courtenay, British Columbia, Canada

Monday, June 25, 2007

EV battery pack conversion complex? Yes and No

Check this simple diagram and ask yourself, ** Can I do this? **




The basic simplicity of the Electric Vehicle can make one wonder at the needless complexity and inflated prices * Big Auto * likes us to believe are warranted for simple transportation.

This is an excellent EV conversion project by Nick = http://DriveEV.com


The converter :
Even the 400v to 12v DC to DC converter need not be connected to the drive current supply.

For accessory lights and battery charging. I would prefer an independent charger system because the converter needs to throw off a lot of wasted heat.

The function of the main breaker is the obvious safety device. Not so obvious is the inertia breaker in case of a collision accident. One more safety feature is the dash mount pull to open the main breaker via mechanical cable tripping.

10 deep-cycle gellCell batteries = 120Vdc @ $120 each = $1200
[ Heavy, should do until light, Hi-density batteries are reasonable in price. ]

400 Amp DC motor
Used DC9 400 amp DC motor Model FB-1 - 4001A = $
[Surplus auction or used military airfield supply]

These are the main elements to consider before getting started. You can get full conversion kits and they generally start at $9K , [ without batteries], so if you go this route it will be a month or two before you break even on gas savings.

Ken, gets his conversion supplies from Canadian Electric Vehicles Ltd Errington B.C. here on Vancouver Island just inland from Parksvill up from Nanaimo.

Canada National Flag




Temptation, . . . Eh? = TG

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Blogger Gayle said...

Hi Johnny.

Have you heard that salt water has been proven to be able to burn? It is possible to make fuel from saltwater to run motors. I have a video up.

11:15 AM  
Anonymous Rodrigo said...

Oi, achei teu blog pelo google tá bem interessante gostei desse post. Quando der dá uma passada pelo meu blog, é sobre camisetas personalizadas, mostra passo a passo como criar uma camiseta personalizada bem maneira. Até mais.

11:02 PM  
Blogger Gayle said...

It's me again... just hoping everything is okay with you and yours since it's been so long since you've posted.

2:25 PM  
Blogger TonyGuitar said...

All is well except there is not enough time to get all the useless fun things done in the summertime... eh? = TG

7:10 AM  
Blogger phil-l said...

Yes, that's a simple EV diagram. But if EVs are to be the solution, the diagram needs to look a lot different than that.

For starters, that schematic includes no provision to charge the batteries. Often a detail that's forgotten until the end of a project. But all EVs need a way to charge batteries - and efficient, effective chargers that maximize battery life are a science unto themselves. Of course, another raft of safety issues show up as well.

The next obvious item is regenerative braking. Yeah, we don't care about such things for simple EVs. But it will be an essential part for EVs that are finally broadly accepted, readily available, and reasonably affordable.

And let's leave some room in the design for things like ultracapacitors as a way to quickly accept regenerative input - and make short bursts of acceleration possible without battery damage. And wiring to support individual battery or even cell-level monitoring to ensure that the beginning of a problem doesn't leave the car stranded at the side of the road.

Certainly traction control and ABS functionality - both of which make sense as a fundamental element of an EV drivetrain, as opposed to an add-on - deserve to show up.

The diagram is a good place to start. But we've got a ways to go!

11:40 AM  
Blogger TonyGuitar said...

You are entirely correct of course. These is merely a block diagram to show how simple the basic system is.

Even with every addition you correctly point to as *required*,
the overall EV is vastly more simple and reliable than any ICE.

I like the idea of a small 3 cyl diesel / bio-fuel gen-charger for the power-pack. One of the few GM [Volt] ideas I agree with.

The 12v service battery charger can be friction or belt drive. The *hot* DC to DC converter is not a good idea in my view. = TG

2:19 PM  
Blogger PGP said...

Re... Your post at SDA about BC Hydrogen busses.

That's 4.5 MILLION dollars each!
What possible justification is there for that cost? Hydrogen fuel cells and all ... there is no possible way that figure is justified!

10:18 AM  
Blogger TonyGuitar said...

Correct! This is Gordon Campbell priming the hydrogen pump with our tax dollars.

Guess he thinks, if you throw money into Hydrogen power, the unit costs will diminish.

And Gordie will take the credit as an important Hydogen pioneer.

This from the guy who gave away modern NDP expensive ferries at 10 cents on the dollar. Off with our nose to spite his face. = TG

10:52 AM  
Anonymous Nick said...


Nick here from DriveEV.com. I just wanted to let you know that in your blog post it appears you mixed up information about my EV conversion (from DriveEV.com) with information about Ken Norwick's EV conversion from his website (http://www.docdockdocuments.com/conversion/ConversionIndex.htm)

For example, the statement "Nick, gets his conversion supplies from Canadian Electric Vehicles Ltd Errington B.C..." is incorrect, as I did not purchase any parts from CanEV for my conversion.

Send me an E-mail if you have any questions and/or would like clarifications about my JeepEV conversion. Hope that helps.

(nick at driveev dot com)

10:29 PM  
Blogger TonyGuitar said...

Nick, Thank you for taking the time to correct me.

More correct to say:
** Several Ev project persons get their supplies from Canadian Electric Vehicles Ltd Errington B.C. **

You put a huge effort into your Jeep conversion, and the excellent detailed blog diary as well.

My 1987 Wagoneer is rust free but built heavy compared to newer Jeeps, you would probably advise a newer lighter vehicle perhaps for EV conversion. A *96 station wagon possibly.

Be sure to look at Nick*s EV project:


Excellent! Like a $200 how to manual for FREE! = TG

11:17 PM  
Blogger TonyGuitar said...

It must be dawning on people by now just how much the Vehicle manufacturers are dragging their feet at filling our demands for clean electric vehicles like the 1993 GM EV-1.

Check ahead to the November 4/07 post about the 4/5 page public relations propaganda from the fork tounged Canadian Vehicles Manufacturers Association.

Sincere? You decide. = TG

9:24 PM  

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