1986 MR2 EV Conversion Notes Ken Chiang

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1986 MR2 EV Conversion NotesKen Chiang
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My Tesla Roadster Requirements

• Get me to and from work
• 5 days a week, 50 miles a day.
• Hilly Terrain
• 9 Grade hill for ½ mile at end of my commute.
• Fast Charge for example, not 12 hours
• Safe

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The main components

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

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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

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How much time?

• Elapsed time 3years
• July'08 July'11
• Actual time 1 year?
• Baby boy!
• Working after work
• No mechanical background

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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 vehicle Bob Brandt

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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

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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

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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.

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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.

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What would I do differently?

• Convert a 4 seater
• New baby boy!
• Can't fit my entire family in my MR2. (
• Start with something with a better body and power
  doors and locks instead of adding on afterwards.

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Other learnings

• Check NEMA connectors monthly!

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Other learnings

• Pay special attention to the bolts on the drive
  train!
• CV joint coming lose can cause a lot of damage!

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Learnings (cont...)

• Design system within specs of each component
• LiFePO4 rated at 4C 4180720amp 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!

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How does my Tesla Roadster compare?

• MR2 ZEV
• 0 to 60 10.8s
• Range 70-90miles
• Max Speed 90mph
• Cost 25k
• New Friends gt 30
• Proud Factor 10
• Knowledge Gained 10

• Tesla Roadster
• 0 to 60 3.7s
• Range 220-300 miles
• Max Speed 125mph
• Cost 100k
• New Friends ?
• Proud Factor 10
• Knowledge Gained 5?

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Loving the Drive!

• Almost 12,000 miles 1400 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)

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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

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Feel free to contact me!

• Ken Chiang
• kchiangusa at gmail dot com
• http//www.mr2ev.com

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Other cool project from our EAA
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Other Cool Projects from our EAA