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1986 MR2 EV Conversion Notes Ken Chiang

1986 MR2 EV Conversion Notes Ken Chiang. The main components. ICE Components removed Replaced by: Radiator system -----> n/a Engine ----------> motor Fuel Tank -----------> batteries & charger Alternator --------> DC/DC converter Starter ------> n/a

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1986 MR2 EV Conversion Notes Ken Chiang

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  1. 1986 MR2 EV Conversion NotesKen Chiang

  2. The main components • ICE Components removed Replaced by: • Radiator system -----> n/a • Engine ----------> motor • Fuel Tank -----------> batteries & charger • Alternator --------> DC/DC converter • Starter ------> n/a • ECU ----------> controller • **The hardest part was figuring out how to fit the battery racks in the small space

  3. Major costs • 180AH 144V LiFePO4.................................$11,000 • Motor.............................................................$1550 • Controller......................................................$1500 • Charger* ….....................................................$2500 • Cables,contactors,DC-DC,instrumentation...$1000 • Adapter plate..................................................$825 • Aluminum racks (materials & welding)........$800 • Misc Tools.....................................................$500 • New suspension/wheel bearings....................$1000 • Other …......................................................$5000

  4. Project Resources (1) • Internet! • Evalbum.com: met Steve McDonald • Electric-cars-are-for-girls.com • Electric Auto Association! • Books: • Haynes Manual for 1986 MR2 • Convert it: Mike Brown • Build your own electric vehical: Bob Brandt

  5. Project Resources (2) • Friends that I've met after I started: • Steve McDonald: 1987 Honda Civic (lead acid) • Honn Chhim: 1987 Honda Civic (LiFePO4) • Michael Brooks: 1990 Honda CRX (lead acid) • Kevin Philips: Aluminum Welder (owns fab shop in Hayward- great work and very reasonable rates) 510-459-8427

  6. Project Resources (2) • Friends that I've met after I started: • Steve McDonald: 1987 Honda Civic (lead acid) • Honn Chhim: 1987 Honda Civic (LiFePO4) • Michael Brooks: 1990 Honda CRX (lead acid) • Kevin Philips: Aluminum Welder (owns fab shop in Hayward- great work and very reasonable rates) 510-459-8427

  7. Project Resources (3) • Suppliers that I've used • EV america in NH: sells kits, offers clutchless design • KTA services: adapter plate for a clutch system. • Manzanita Micro: nice PFC Battery charger and LiFePO4 distributor • CleanAutoLLC: EV display 2 (highly recommended) • Alco Metal: cheaper AL than Home depot • Naylor steel: anything steel • PickNPull: salvage yard for finding misc car parts.

  8. Good Decisions • LiFePO4 vs. wet lead acids • Longer range • Cheaper per year • Better performance • Less maintenance and mess • Aluminum racks • Saved 150 lbs • Coulomb counting fuel gauge vs. voltage based • EV display 2 has a lot of useful features and accurately tells me how much “fuel” left.

  9. What would I do differently? • Convert a 4 seater • New baby boy! • Can't fit my family in my MR2. :( • Start with something with a better body and power doors and locks instead of adding on afterwards.

  10. Other learnings • Pay special attention to the bolts on the drive train! • CV joint coming lose can cause a lot of damage! • Check NEMA connectors monthly!

  11. Learnings (cont...) • Design system within specs of each component: • LiFePO4 rated at 4C 4*180=720amp draw max • ADC 8” motor is rated up to 120V, don't run 144V! • LiFePO4 must be banded to prevent expansion during charge and discharge cycles • LiFePO4 should not be oriented flat with terminal on side (per manufacturer) • Can't get white carpool sticker anymore? (tried 3 times) • Manzanita PFC chargers not isolated, don't touch terminal while charging!

  12. Loving the Drive! • Almost 8,000 miles == $1k savings in gas • Solar panel payback: 22 years to 8 years. • http:// www.mr2ev.com • Places that I've been in my EV from my home in CV • SFO 54 miles • Livemore 48 miles • San Jose 66 miles • San Rafael 76 miles (charged at parking garage) • Planning farther trips by utilizing J1772 adapter for public charging for free! (until 2013)

  13. Maintenance Checklist • Check Tire pressure Monthly • Check high current connections Monthly • Measure top/low voltages Monthly • Check NEMA connectors Monthly • Check all bolts (racks/cv shaft,etc) every 6 months • Rotate Tires every 6 months • Check Brakes every 6 months • Top off transmission fluid? every 6 months • Check motor brushes every 1 year

  14. Ken Chiang kchiangusa at gmail dot com http://www.mr2ev.com Feel free to contact me!

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