What a Concept Electric Cars and Clean Air

1. What a Concept Electric Cars and Clean Air C2EC2T Commuter Conversion Electric Car Class for Teachers and EV Enthusiasts 4th Annual Workshop San Diego City High School Coordinators: Abrán Quevedo (Mr. Q) and Jon Karanopoulos July 28th to August 8th, 2008

2. The Project The C2EC2T workshop is a project-based instructional offering for teachers and electric vehicle enthusiasts. Workshop participants will learn how to convert a small ICE (Internal Combustion Engine) car into a NICE (No Internal Combustion Engine) car powered by batteries. A collaborative team approach will be used to brainstorm, plan, design, and convert the project car within the ten-day period.

3. DAILY ROUTINE PROPOSED SCHEDULE • Workshop will be open from 7:30 AM to 8:00 AM for coffee and pastries. Class will start promptly at 8:00 AM each morning in the classroom. • Mr. Q and Mr. Karanopoulos will introduce the guest speaker for the day and the EV topic area to be covered. The presentation will take one hour and the guest presenter will stay through the lunch period so that individual participants may have an opportunity to ask questions. • Immediately following the guest presentation, Mr. Q and Mr. Karanopoulos will conduct a daily PRE-BRIEFING of activities to be undertaken, including tools needed, work station location, and group assignments. Participants will then go to their designated team area to start the day’s work • At 11:30 a.m. a light (working) lunch will be provided in the workshop and classroom area. • Work will stop at 2:30 p.m. for clean-up and DE-BRIEFING. The purpose of the de-briefing will be to evaluate each day’s progress and address any glitches and/or concerns.

4. Shop Set-up and Clean-up Procedures • There will be designated areas in the shop for specific team objectives and functions • Participants will be assigned to specific teams based on similar skills and preference • Team leaders will be selected based on skills and capabilities needed to meet team objectives • Final decisions related to all phases of the conversion process and applications will be made by the C2EC2T coordinators and team leaders • Clean-up procedures will be the responsibility of all workshop participants and will be based on the principle of “a place for everything and everything in its place”

5. Tools and Equipment • Car lift • Engine hoist • Hydraulic floor jack • Safety stands • Pneumatic tools and equipment • Electric saber saw • Hand tools • Welding equipment • Safety gear and apparel • Specialized electric car conversion tools, equipment, and materials

6. Daily Activities ScheduleWeek 1 • Day 1-The coordinators will welcome everyone and a round robin self-introduction of workshop participants will follow. Jon Karanopoulos, San Diego High School Auto Shop teacher, will give a tour of the auto shop. Our first presenter, Bill Hammons, President of the Electric Vehicle Association of San Diego (EVAOSD), will deliver his presentation on EVAOSD history and other EV organizations in the United States and the world. Mr. Hammons will also address current EV issues related to global warming and offer a general review of the latest EV technologies and EVents. After Mr. Hammons’ presentation, lunch will be served and ample socializing time will be provided on our first day together. After lunch, the coordinators will continue with orientation and distribute books, binders, workshop T-shirts, and homework assignments. The introduction of special tools required for EV conversions and basic EV components will follow. A safety presentation, consisting of (a) safety recommendations for EV conversions, (b) safety procedures, and (c) safety apparel, will also be given. Shop clean up procedures, designated team areas, selection of team leaders and members, team brainstorming sessions will follow. Participants will then be provided an opportunity for a hands-on activity in the use of EV car tools and components. Before leaving for the day, we all sing “Puff the Mechanical Dragon”, our theme song. • Day 2 – Mr. Q will introduce Frank Trejo, Regional Sales Manager of Powerstride Battery. Frank’s topic area is “Deep Cycle Batteries” for EV conversions. Mr. Q will then conduct a pre-briefing for the day and assign work groups and work areas with tasks to be completed. After lunch, work will continue until the clean-up and de-briefing period at which time book chapter assignment will be given out. • Day 2- Morning briefing, presentation by Mike Parker( title), presentation by Mark Kearns and documentation team < LUNCH BREAK> All teams begin work in designated areas, shop clean-up and afternoon debriefing last 30 minutes of class. Field Trip #1 to Del Mar Fair • Day 3- Morning briefing, presentation by Mike Parker( title) presentation #1 by Russ Lemon Performance Projections <LUNCH BREAK> All teams begin work in designated areas, shop clean-up and afternoon debriefing last 30 minutes of class. • Day 4- Morning briefing, presentation by Mike Parker (title) presentation #2 by Russ Lemon Performance Projections < LUNCH BREAK> All teams begin work in designated areas, shop clean-up and afternoon debriefing last 30 minutes of class. • Day 5- Morning briefing, presentation by Mike Parker (title) presentation #3 by Russ Lemon: ‘Performance Projections <LUNCH BREAK> All teams begin work in designated areas, shop clean-up and afternoon debriefing last 30 minutes of class.

7. Daily Activities ScheduleWeek 1 (continued) Tuesday – Jim Bohorquez will discuss general principles and dynamics related to a comparison of electric cars and gas cars, with a focus on the advantages and disadvantages of both. Topic areas to be covered: wind resistance, operating costs and environmental issues. The coordinators will then conduct a pre-briefing for the day and assign work groups and work areas with tasks to be completed. After lunch, work will continue until the clean-up and de-briefing period at which time book chapter assignments will be given out. We will end by singing “Puff the Mechanical Dragon.” Wednesday - Frank Trejo, Regional Sales Manager of Powerstride Battery. Mr. Trejos’ topic will be Deep Cycle Batteries for EV conversions. The coordinators will then conduct a pre-briefing for the day and assign work groups and work areas with tasks to be completed. After lunch, work will continue until the clean-up and de-briefing period at which time book chapter assignments will be given out. We will end by singing “Puff the Mechanical Dragon.” Thursday – Russ Lemon, retired electrical engineer. Mr. Lemon’s presentation will focus on technical aspects of electric car performance projections. The daily pre-briefing will follow after which shop participants will begin the day’s work. The day will end with clean-up and de-briefing. Friday – Lee Campbell, retired electrical engineer. Mr. Campbell’s topic will be EV Conversions and Solar-assists. Mr. Campbell’s Chevy S10, which was converted two years ago, will be made available. Daily pre-briefing will follow after which shop participants will begin the day’s work. The day will end with clean-up and de-briefing.

8. Daily Activities ScheduleWeek 2 Monday – William Rhodes, new owner of KTA Services, Inc. KTA Services is a major player in the provision of EV components for gas-to-electric conversions. Component parts will be presented and current costs indicated. After the presentation, we will have the pre-briefing and get right to work. Tuesday – Jason Greenblatt, M.S. in Mechanical Engineering, and an employee of San Diego Gas & Electric. Mr. Greenblatt’s topic area will be low-rolling resistance tires for EV applications. Following will be the daily pre-briefing, morning work, lunch break, afternoon work, debriefing and “Puff…” Wednesday – Dave Dahl, professional electrician. Mr. Dahl will give a presentation on his recently converted Chevy S10. Following will be the daily pre-briefing, morning work, lunch break, afternoon work, debriefing, and “Puff…” Thursday – Michael T. Kadie, EV owner. Mr. Kadie will address kit car conversions. A kit car will be present for viewing by workshop participants. Following will be the daily pre-briefing, morning work, lunch break, afternoon work, debriefing, and “Puff…” Friday – Dave Grove owner, and Bob Van Gorder conversion expert, will address classic car conversions and present a converted 1936 RR. Dave Cutter of the Village Energy web site will be talk about the media and how to address them regarding your future electric vehicle. Following will be the daily pre-briefing and presenting of certificates, driving the new electric car, sharing a final meal, followed by singing “Puff the Mechanical Dragon” one last time!

9. PROJECT CAR PREPARATION • Removal of engine, gas tank and lines, exhaust system, radiator and hoses, and other miscellaneous ICE components • Degrease and steam clean engine compartment and car underbody • Brake system upgrade • Suspension system upgrade • Minor body work, preparation, and painting of project car

10. Collaborative Team Area1 Small Gauge Electrical • Design and draw wiring diagram and determine component locations on project vehicle • Assemble small gauge wiring harness with connectors and attach to major and minor components • Install gauges, wires, relays, circuit breakers, and other electrical parts as specified by the wiring diagram • Confirm that headlights, taillights, turn signals, windshield wipers, and other related parts are operational • Address any additional issues regarding small gauge wiring as necessary

11. Collaborative Team Area2 Large Gauge Electrical • Plan and design battery pack locations and cable placement • Hook up and test electric motor prior to attaching it to the transmission • Test each new 12-volt battery for surface charge and compare to specifications • Install battery box in vehicle in best possible location for most positive and most negative terminals • Perform test and service a two-year-old battery pack system in a similar commuter conversion car

12. Collaborative Team Area3 Battery Pack Frame Fabrication/ Installation • Plan and design angle iron battery pack frame for front and rear locations • Fabricate plastic battery pack boxes to fit into angle iron frames • Test chosen locations for battery pack frame on vehicle before installation in project car • Paint frame with rust-proof primer followed by glossy finish paint • Install battery packs in project car • Install batteries into frames and secure them

13. Collaborative Teams Area4 Adaptor Plate Installation • Steam clean transmission housing • Fabricate electric motor mount per KTA instructions and illustrations and attach to existing car body bracket • Check adaptor plate for proper alignment to transmission and electric motor • Remove flywheel ring gear and machine flywheel to reduce excess weight • Install flywheel, clutch disc, pressure plate, and motor output shaft coupling per specifications (magic number) • Attach motor, pressure plate, transmission, and place each onto engine hoist • Install motor and transmission assembly into project vehicle

14. Collaborative Team Area5 Low-rolling Resistance Tires • Locate and acquire the recommended low-rolling resistance tires for the project vehicle • Present information and application charts on low-rolling resistance tires to workshop participants • Remove existing project car tires and install new low-rolling resistant tires • Test drive and chart low-rolling resistant tire performance such as handling and additional range gained • Investigate availability and cost of aluminum wheels for the project vehicle

15. Collaborative Team Area6 Power Brake • Preassemble power brake pump and vacuum chamber per KTA instructions • Fabricate brackets and base as needed • Review placement of power brake pump assembly unit with coordinator before installation • Install power brake pump assembly into project car • Test the unit and make any adjustments and/or alterations as needed for proper operation

16. Collaborative Team Area7 Reassembly of Project Car • Clean and reinstall floor covering and car seats; paint over and/or reinstall car trim • Design and install project car logos, icons, and other final items as decided • Clean and wax exterior paint, molding, and final prep interior • Undertake any additional detailing as needed

17. Collaborative Team Area8 Workshop Documentation • Take and collect photographs/videos of workshop participants during ten-day C2EC2T • Assemble a multi-media presentation of C2EC2T workshop • Distribute workshop presentation for participant portfolio and funding source documentation • Contact local media for possible press coverage of C2EC2T workshop • Brainstorm preliminary ideas and location for future C2EC2T workshops

18. All Team Topics9 Related EV Topics A.Roadside opportunity charging stations B. Electric vehicle range extenders C. Solar photovoltaic panels (roof racks) D. Battery trailers E. Regenerative braking systems F. Amtrak city to city transportation for electric vehicles G. Job development and future opportunities in the alternative vehicle automotive career area H. Entrepreneurial opportunities for electric vehicle component sales and for the establishment of professional electric vehicle conversion shops I. Global warming, the Greenhouse effect, the melting of polar icecaps and Greenland ice shield at an alarming rate J. The peaking of world oil production as of 2006 and the need to establish alternative fuel sources K. Any additional topic areas that may be introduced