If you’re building an electric car nowadays, you’re probably looking at taking a normal, gas-powered car and replacing the engine and transmission with an electric motor and batteries. [Gahaar] thought this is a rather dumb idea; all the excesses of an internal combustion-powered car, such as exhaust, cooling, differential, and fuel storage is completely unnecessary. Building a new electric car from the frame up is a vastly more efficient means of having your own electric car. So that’s what he did.
[Gahaar] build his new chassis around a single box made of 3mm aluminum sheet. Attached to this box are two AC induction motors at the rear of the car, negating the need for a differential, with 45 lithium cells stuffed into the middle of the box. There’s no gearbox here, greatly reducing the complexity of the build, and with the batteries providing 145V and 100Ah, this simple car has more than enough power for a lot of fun.
The suspension and steering were taken from a wrecked car, in this case a Mazda MX5, or Miata for those of us in North America. The Miata suspension easily unbolts from the frame of the wrecked car, and with just a little bit of welding can easily be attached to the new electric chassis.
Even though [Gahaar]’s car is basically just a bit of aluminum, motors, suspension, and batteries, he’s getting some awesome performance out of it; he estimates a top speed of 100mph with about 60 miles per charge. It’s an awesome way to get around the farm, and with a custom fiberglass body, we can easily see this being one of the coolest electric vehicles ever made.
You probably recall the Chibikart from posts earlier this summer, which is one of an endless list of EV projects [Charles] has up his sleeve. He’s been teaching MIT students how to build EV karts for a while now, and this total-recap “2.00gokart” novel is [Charles’s] way of sharing the wealth. This is more than a simple how-to guide, though. Instead, it reads like a teacher’s edition of GoKarting 101, with a few brief and important histories, walk-throughs of how the class evolved, exhaustive links to vendors, graphs, videos, and plenty of reference and documentation.
If you have even the slightest interest in electric vehicles, do yourself a favor and give it a browse. There are a couple of videos after the break, and if you need some more motivation, check out the EV skateboard that uses a lot of the same parts.
After removing the engine, fuel tank, exhaust, radiator, and all the other things that make an internal combustion engine work, [Kurt] installed a high power motor, controller and 72 lithium phosphate batteries weighing in at over 500 pounds. He’s put over 300 miles on the car in the last few months while working out the kinks, but now he’s finally gotten the bugs out of the system allowing him to take it up to some relatively high speeds.
Already [Kurt] has taken his new ride to 100 mph and done a little bit of range testing that told him he should expect around 40 miles per charge in his new ride. It’s not exactly what he hoped, but more than enough for a few trips around town while riding in style.
After the break is a video [Kurt]’s first test drive of his electric Porsche.
The Chevrolet Volt is one of the top contenders in mass-market electric vehicles. Now you can get a look at the components that make up the electrical system with this Chevy Volt teardown article.
The adventure starts with a look at the 288 cell battery. It forms a T shape and takes up the space that forms the hump down the center of the interior of a vehicle. Theses have a liquid cooling system build into the enclosure to make sure things don’t get too hot during use or charging. The sights are then set on the control and monitoring hardware, and there’s a lot of it. In fact, the image above is an overview of the eighteen modules that pull the new plug-in EV technology together. If you’re brave enough to void the warranty on one of these, this should be a helpful road map to get you started.
Has anyone seen a teardown of the home charging station for one of these?
[Soren Coughlin-Glaser] runs a mobile photobooth in the Portland area. It’s built inside of an electric Volkswagen bus. The conversion to electric hasn’t been easy though. He’s spent most of the last few months rebuilding it after an electrical fire. Last fall he installed a 9 inch electric motor from Hi-Torque Electric after his smaller one blew up. We really like this project and look forward to seeing it back on the road… once he replaces his stripped transmission coupler.
Thanks to a Danish Engineer, you can turn pretty much any car into a hybrid. The addition is made in the form of a bolt on motor. As you can see in the picture, there is a motor that attaches to the rear wheels adding an additional 7 Hp. The batteries are stored in the trunk. Kits start at $3,500 and go up to $4,500 depending on battery selection. At least, that’s what they will be when they finally go on sale.
DPX Systems seems to deal exclusively in devices powered by handheld drills. In addition to the mini bike in the video above, they’ve made systems for wheelchairs, toolboxes, and hoists. The device costs $630, but we know most of you just need prompting that something is possible to be well on your way to building your own version. We’re still more fond of weed whacker machines.