My attempt at creating an inexpensive electric car
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I could go out and spend untold thousands and buy an electric car or I could try and build my own on the cheap. I have been interested in building on for many years and actually started to convert a 1953 Vauxhall Velox 10 years ago. Had to gave up due to time constraints and the eventual realization that this was not the most practical way to do this. The vehicle, although free, was to difficult to use as spare parts were unheard of and it wasn't the most mechanically sound choice. Fast forward with a lot of reading and researching and I came to one conclusion. To do this best, I needed it to be cheap to acquire and cheap to create. In order to make this inexpensive, I needed to keep the weight down and if I kept the speed down then I could use a smaller motor and less batteries which would accomplish that goal. I was able to get a new Etek for $550 and then the hunt was on for a suitable donor car. Research found one bizarre anomaly. In 1985, you could purchase new over 20 different cars in Canada that weighed less than 2000 pounds ( 900 KGs. ). Jump ahead to 2005 and this number went down to 3, 2 Smart cars and a Citroen 2CV. This lead me to my choice being either a Nissan Micra or one of the Suzuki/Chevy/Pontiac/Geo Swift/Sprint/Firefly/Metro and the older the lighter. I was fortunate to acquire a 1991 Chevy Sprint at a local auto wrecker that only needed the engine pulled to be useful. So what you see here is the start of that process.
My finished plan is to rebody the Sprint with lightweight fibreglass panels but I must first prove the viability of the plan. All I want from the car is to be able to drive a maximum of 35MPH ( 60 KMH ) and have a minimum range of 15-20 miles ( 20-30 km ) which would get me to work and back every day with some to spare. If I can get more than this, then that's a bonus. I chose the Sprint after experimenting with one to see if I could bring the weight down. I took it and removed the doors, rear hatch, back seat, engine and roof and I weighed all these parts once they were removed. This took off over 400 lbs. from a 1600 lb. vehicle, so this gave me hope. Unfortunately that specific vehicle was not road worthy and never would be again. But the one pictured below is a perfect specimen for my plan. As such I have included some pictures showing the conversion to date.
Not much to look at and a putrid shade of green, but it's amazing what one can do with some tools and a reciprocating saw.
My son had a wonderful time helping me dis-assemble it and he found over $1 in spare change inside.
Just finishing up some projects at home and then it can come home for the initial conversion. I will add the Etek and 4 batteries, a seat and a home-built controller, then I will take it out for some road testing, with the approval of the RCMP, just to prove it works. Once that is done then it's time for some much needed bodywork and paint, but only once it proves my theory. If the Etek proves to be too gutless, them I will look at changing it to a Perm with 6 batteries. The hope is to keep the curb weight as low as possible and hopefully down around 1000 - 1200 lbs.
August 25, 2008
When I got the Sprint home, it was missing the transmission but it at least had all 4 wheels. I managed to brute force the replacement tranny into place and get it connected up. With the help of a co-worker, we manufactured a coupling to mate the Etek to the splined shaft of the tranny. Unfortunately I didn't take a pic of that but if/when I pull the Etek off, I will do that. It's actually a thing of simple beauty for a couple of geeks to create. We took a piece of 2" round steel, drilled it for the Etek shaft and keyway, cut the centre out of the clutch plate and set it nicely into the coupling and welded into place. I have managed to install the Etek onto the transmission directly without a clutch, using a piece of 5/8" plywood for now as a template/test. I have actually driven the car in my driveway using only 1-12v battery and was able to get it rolling in all 5 forward gears. No cotroller, just jumper cables between the motor and the battery. I have included a video of it in action at the end.
This is the car in rolling ready to go mode. Not much to look at but it still only a testbed for the ideas and a serious work in progress.
Here's the nice little Etek installed and functional. I will need to rebuild the front motor/tranny mount but for now it works.
And now for the moment of glory. IT'S ALIVE !!!! I know for some this isn't much, but remember my design spec. is only to be able to go 60kmh or 35mph and have a range of 20-30 km or 15-20 miles. Click on the link to watch the movie of the car in action.