Converting gas vehicle to electricity with students

[Josh Merrow]

Hi everyone

I'm interested in doing an EV conversion with some interested students next year. It seems you can pull the motor, cooling, exhaust and fuel systems out of a lightweight car with a manual transmission and bolt (with some machining to make an adapter plate and a shaft coupling) a used DC forklift motor right to the transmission. Add batteries, a charger, an electric vacuum pump and tank for the power brakes, and you have an electric city car. 

It seems like a fun long-term project requiring a good amount of research, theory, and hands-on activity with a cool payoff at the end. Has anyone tried this or anything similar?

Thanks

Josh

[Kenton A. Hoover]

I haven't done one (we don't have a suitable facility) but have looked into the details. While the mechanicals are as simple as you suggest (except you forgot fabbing a mount for the motor) the power electronics aren't quite that simple and are the most likely place to get someone hurt/blow something up. Also, I'd look into regenerative braking and eliminate the power brakes, or at least run the power brake vacuum pump off a separate electrical chain.

-- 
Kenton A. Hoover

Director of Operations / Engineering & Industrial Arts Teacher

Tehiyah Day School

2603 Tassajara Avenue

El Cerrito, CA 94530

kaho...@tehiyah.org

+1 510 233 3013 (main)

+1 510 730 7098 (direct) 

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[John Umekubo]

This might be a helpful resource, or at least a source of inspiration. 

http://minddrive.org/

I've not been there, but read about them in Ken Robinson's book, Creative Schools. 

- John

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