tag:blogger.com,1999:blog-387292302024-03-05T00:06:23.685-08:00Electric VW ProjectThis is a project to convert a gas powered 1986 Volkswagen into a 100% electrically powered vehicle. The conversion will entail removing all the gasoline associated equipment and replacing with an electric motor, sixteen 6-volt golf cart batteries and associated electronic controls. The batteries will be recharged using standard 115 or 230 volt household outlets. Initial performance is expected to be: 30-40 mile driving range between recharging and an available highway cruising speed of 65 MPH.Unknownnoreply@blogger.comBlogger80125tag:blogger.com,1999:blog-38729230.post-32717472899702764752022-11-01T12:55:00.000-07:002022-11-01T12:55:05.509-07:00It comes down to cost ... every time.<p> <span style="background-color: #141414; color: white; font-family: trebuchet; font-size: 13px;">November1, 2022</span></p><span style="background-color: #141414; color: white; font-family: trebuchet; font-size: 13px;">Evaluating the cost of a 1000 amp controller vs. repairing my current 500 amp Curtis 1231C controller, considering my usual past usage history, I decided to repair the Curtis. ($800 vs. $2500) I will add a little additional cooling for the controller. Method and means yet to be decided.</span>Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-38729230.post-73005946330323768962022-09-11T20:38:00.001-07:002022-09-11T20:38:36.981-07:00Fried Eggs and Ham ...<p></p>
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<span style="font-family: trebuchet;">Short story:</span><div><span style="font-family: trebuchet;">Friday,
9/9/2022: Warm day 90+, pulling max power, up a fairly long grade on
Hwy 195. At the top of the hill, I let up on the accelerator pedal and
the power immediately dropped to zero. I pushed the pedal back in a bit
and "whamo" it went to full 100% power. Let off and zero power. Using
FULL ON/FULL OFF, I ratcheted into the Pullman Building Supply parking
lot. The good people there helped push me into a suitable parking spot
whereby I called a tow truck. Controller fried!</span></div><div><span style="font-family: trebuchet;"><br /></span></div><div><span style="font-family: trebuchet;">I
have been looking for an excuse to upgrade from the current 500 Amp
controller to a 1000 Amp controller. I think I just found one!
<smile><br /></span><div><span style="font-family: trebuchet;"><br /><br /></span></div></div>Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-38729230.post-37005403085173280732019-08-23T20:38:00.000-07:002019-08-23T20:38:00.369-07:00<h2 style="text-align: center;">
<span style="font-family: "Trebuchet MS", sans-serif;">Electric VW finally coming out of "hibernation"<br />after five years in the barn.</span></h2>
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<span style="font-family: "Trebuchet MS", sans-serif;">I had been keeping the VW in the barn for over five years, waiting for inexpensive Lithium-Ion (LI) batteries to become available. Never happened. Last fall I bought a complete LI battery pack out of a Nissan Leaf electric vehicle. I had planned on reconfiguring it for the VW. After a lot of research, I realized the cost exceeded the benefit. I sold it on eBay.</span></div>
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<span style="font-family: "Trebuchet MS", sans-serif;">The original golf cart battery pack worked well. I drove it for five years and 20,000 miles. The new battery set will have slightly more energy, per battery, plus I have added two more, for a total of 18. This raised the nominal voltage from 97 volt to 108 volts. </span></div>
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<span style="font-family: "Trebuchet MS", sans-serif;">The previous driving range was 45 miles, more or less, with a cruising speed of 55 MPH. Top speed was 75 MPH. With the larger pack, I expect about ten percent more range and speed. (I will report the results, later.)</span></div>
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<span style="font-family: "Trebuchet MS", sans-serif;">It has been hard to find the time to work on the VW rehab because of our expanding family business. (<a href="http://www.rjrtractor.com/">www.rjrtractor.com</a>) It's been an hour, or two, here and an hour, or two, there. I am hoping to spend most of tomorrow, Saturday (8/24/2019) working on the car … and hoping there are not too many "Honey Do" projects.</span></div>
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<span style="font-family: "Trebuchet MS", sans-serif;">If I get a full day tomorrow to work, I will probably be ready to make a first test run. It will take five or six RUN/RECHARGE cycles to get the battery pack conditioned for max output.</span></div>
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<span style="font-family: "Trebuchet MS", sans-serif;">For recharging, I have updated my Manzanita Micro PFC25 Charger to the latest configuration. It should be much easier to use and safer for the batteries. I am expecting it will take about one hour of recharging, using a 240 volt supply, for every ten miles of driving. An 18 miles run into and return from town will take about two hours of charging.</span></div>
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<span style="font-family: "Trebuchet MS", sans-serif;">Since virtually all the power for charging will come from our 10kW solar system, the cost to drive the car will be minimal.</span></div>
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<span style="font-family: "Trebuchet MS", sans-serif;">Stay tuned ... </span></div>
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgTeyZ8Lsf0LYugqxU7sT19Ly86muTL3bdM89wAPwc4OxlQMoYpc9oNLB3shcDGvGhHiysZROnl9ARV_IG2kXibuXsF_r6EcsfPaujBYQbkXrdUzOYhGWLfmVOTd6-GuPKbGYGx/s1600/IMG_0012.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="1067" data-original-width="1600" height="266" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgTeyZ8Lsf0LYugqxU7sT19Ly86muTL3bdM89wAPwc4OxlQMoYpc9oNLB3shcDGvGhHiysZROnl9ARV_IG2kXibuXsF_r6EcsfPaujBYQbkXrdUzOYhGWLfmVOTd6-GuPKbGYGx/s400/IMG_0012.JPG" width="400" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;"><span style="font-family: "Trebuchet MS", sans-serif;">Center "Saddleback Battery Holders located under the rear seat. (Two added batteries)</span></td></tr>
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiR5aQO6iCthcEcH16RCQ-woWPwNHm7NtnolMOl1K6Q0p9RtYPtmEhO0rMGZFjbXJ-gRo4yxVYqdJRIuItpz0KgSLKj_5bhF_tAAiI4oX5bgIA_BIZgHageVrI0RpJ8oSx3Jir4/s1600/IMG_0013.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="1067" data-original-width="1600" height="266" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiR5aQO6iCthcEcH16RCQ-woWPwNHm7NtnolMOl1K6Q0p9RtYPtmEhO0rMGZFjbXJ-gRo4yxVYqdJRIuItpz0KgSLKj_5bhF_tAAiI4oX5bgIA_BIZgHageVrI0RpJ8oSx3Jir4/s400/IMG_0013.JPG" width="400" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;"><span style="font-family: "Trebuchet MS", sans-serif;">Front Battery Pack Installed</span></td></tr>
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhlS9_usFMNzbSO80jp6XaOpoDWoGF381StOMpFx7N8iXNj-jYnHAfU5AztKs6b-PkDB8ynnMqKojziRVhivdeA8RU7K_wXASxAxqe-B6wfyCNg_lTPNQvQCc0o17ZooaD4hFGd/s1600/IMG_0017.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="1600" data-original-width="1067" height="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhlS9_usFMNzbSO80jp6XaOpoDWoGF381StOMpFx7N8iXNj-jYnHAfU5AztKs6b-PkDB8ynnMqKojziRVhivdeA8RU7K_wXASxAxqe-B6wfyCNg_lTPNQvQCc0o17ZooaD4hFGd/s640/IMG_0017.JPG" width="426" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;"><span style="font-family: "Trebuchet MS", sans-serif;">US125 Golf Cart Batteries (Total of 18 in car)</span></td></tr>
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgFY0p5LQGOBU14_WGNj0hkTIdfhxZFW-pnUgybyn6M7G255twyo7zIh1EAvCn5eTttVQJ-Nyo7_HaKWER5ruE0sAjRiPrK5oeQSwy2n-DGYmqYYCiYoRaOWhz0-SDICYFFdb1k/s1600/IMG_0019.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="1067" data-original-width="1600" height="266" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgFY0p5LQGOBU14_WGNj0hkTIdfhxZFW-pnUgybyn6M7G255twyo7zIh1EAvCn5eTttVQJ-Nyo7_HaKWER5ruE0sAjRiPrK5oeQSwy2n-DGYmqYYCiYoRaOWhz0-SDICYFFdb1k/s400/IMG_0019.JPG" width="400" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">"Blackie" the Tech helper. (Stray cat that adopted us about a year ago.)</td></tr>
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgG9fby0HwouRiYV2ORGXeCxkFHg3vqEKbqyS_an4X75xVjNPSJYs5_ot-YlfWp6JA6XUSvXnWpJHBD0zAj6_SmZjl5POS9DtBESDIQfDy9k-MTg5ftVas5HbLEDhSsQR1dSGi2/s1600/IMG_0015.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="1067" data-original-width="1600" height="266" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgG9fby0HwouRiYV2ORGXeCxkFHg3vqEKbqyS_an4X75xVjNPSJYs5_ot-YlfWp6JA6XUSvXnWpJHBD0zAj6_SmZjl5POS9DtBESDIQfDy9k-MTg5ftVas5HbLEDhSsQR1dSGi2/s400/IMG_0015.JPG" width="400" /></a></td></tr>
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<span style="font-family: "Trebuchet MS", sans-serif;">Rear Battery Pack Installed</span></div>
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<span style="font-family: "Trebuchet MS", sans-serif;"></span><br />Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-38729230.post-10437329312232779672018-12-11T12:18:00.000-08:002018-12-11T12:21:19.688-08:00<h3 style="text-align: center;">
<span style="font-family: "trebuchet ms" , sans-serif; font-size: large;">Ho-Ho-Ho</span><span style="font-family: "trebuchet ms" , sans-serif; font-size: large;">... <span style="font-size: x-small;">not so much!</span></span></h3>
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<span style="font-family: "trebuchet ms" , sans-serif;"> 12/11/2018</span></span></h3>
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<span style="font-family: "trebuchet ms" , sans-serif; font-size: large;">Snowing today.</span></h3>
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<span style="font-family: "trebuchet ms" , sans-serif; font-size: large;">VW is sitting exactly as it was in the last post. I hope to get back to the lithium installation in January. </span></h3>
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<span style="font-family: "trebuchet ms" , sans-serif; font-size: large;">Golf cart fixed:<br /> <br />> Bad controller - installed new Alltrax 400 amp controller.</span></h3>
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<span style="font-family: "trebuchet ms" , sans-serif; font-size: large;">> Left axle broke and the wheel fell off! Replaced the axle. (Bought from Buggies Unlimited - a highly recommended company.) </span></h3>
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<span style="font-family: "trebuchet ms" , sans-serif; font-size: large;">> Installed two solar panels on the top of the cart, replacing the plastic top. I used a "boost type" charge controller to charge the 48vdc battery pack. I have been using the cart for running around the ranch for several months and have not had to use any aux. charging.</span></h3>
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<span style="font-family: "trebuchet ms" , sans-serif; font-size: large;">> Added two LED driving lights. Mounted one on the left front edge of the solar module and one on the right front edge. Works GREAT! </span></h3>
Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-38729230.post-87713234019342048212018-07-31T13:11:00.000-07:002018-07-31T13:11:22.084-07:00<div style="text-align: center;">
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<span style="font-size: large;"><span style="font-family: "Trebuchet MS", sans-serif;">No progress on VW</span></span></div>
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<span style="font-size: large;"><span style="font-family: "Trebuchet MS", sans-serif;">Too many "must do" projects, right now.</span></span></div>
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<li><span style="font-size: large;"><span style="font-family: "Trebuchet MS", sans-serif;">Broken water line to our underground sprinkler system. Lawn looks completely disreputable i.e., looks like hell!</span></span></li>
<li><span style="font-size: large;"><span style="font-family: "Trebuchet MS", sans-serif;">Electric golf cart suddenly quit last week. I need to troubleshoot it and fix. Getting tired of long walk to the barn/shop and back several times a day.</span></span></li>
<li><span style="font-size: large;"><span style="font-family: "Trebuchet MS", sans-serif;">Weeds growing like there is no tomorrow. I need to start making that happen.</span></span></li>
<li><span style="font-size: large;"><span style="font-family: "Trebuchet MS", sans-serif;">Wife and I picked up and hand unloaded 1200 lbs. of chicken feed. </span></span></li>
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Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-38729230.post-37288846010708283992018-07-27T18:53:00.003-07:002018-07-27T18:53:29.646-07:00<div class="separator" style="clear: both; text-align: center;">
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiOx7BsSo8mQkTnP1PBwj8PWQ9Q-qd5z8o81AOkvXDyKvvFqM7F2MDN9CzyNMVwZLR_ckSw53luW5_duLC1Mymx1JaVzxe4q4g7f9h4FcCkvN_RmsW5x3kKlwVyI52MgOJcALcE/s1600/VW+in+barn.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="400" data-original-width="600" height="265" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiOx7BsSo8mQkTnP1PBwj8PWQ9Q-qd5z8o81AOkvXDyKvvFqM7F2MDN9CzyNMVwZLR_ckSw53luW5_duLC1Mymx1JaVzxe4q4g7f9h4FcCkvN_RmsW5x3kKlwVyI52MgOJcALcE/s400/VW+in+barn.jpg" width="400" /></a></div>
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<span style="font-family: "Trebuchet MS", sans-serif; font-size: large;">For the last five years my Electric VW Cabriolet has been "lounging" in my barn. Prior to the "internment" I drove it almost 20,000 miles, until the original set of 16 golf-cart batteries finally pooped out. It was my intent to replace the "flooded lead-acid" batteries with Lithium cells. At that time, Lithium was very expensive. I calculated to obtain the same performance, the Lithium battery pack would cost around $12,000. I decided to wait until the cost declined substantially.<br /> </span></div>
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<span style="font-family: "Trebuchet MS", sans-serif; font-size: large;">Gradually, the cost for Lithium dropped ... but until last years, it was still over $7,000. With the wide acceptance of comsumer electric vehicles, such as the Toyota Prius, the Chevrolet Volt and the Nissan Leaf, there were a certain number of these vehicles that ended up crashed. One vehicle, in particular, the Nissan Leaf, had a Lithium battery pack that was quite adaptable to custom-made electric vehicles. Many were salvaged.</span></div>
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<span style="font-family: "Trebuchet MS", sans-serif; font-size: large;"> This is a battery pack from a Nissan Leaf that I purchased last week. It consistes of 48 lithium modules, each about 8 vdc, for a total of about 385 vdc. Since my VW's controller has a maximum voltage rating of 144 dvc, I will split the battery pack into three parallel strings of 16 modules, each, for an output voltage of 128 vdc. (My original golf cart battery pack was 96vdc.)</span></div>
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<span style="font-family: "Trebuchet MS", sans-serif; font-size: large;">With the original battery pack, my maximum range was about 50 miles and a top speed of 65 mph. With this new lithium pack, I am hoping for about 50% great numbers. </span></div>
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<span style="font-family: "Trebuchet MS", sans-serif; font-size: large;">Follow along, from day-to-day, as I upgrade the vehicle.</span></div>
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<span style="font-family: "Trebuchet MS", sans-serif; font-size: large;">My hope is to be up and running by mid-August.</span><span style="font-size: large;"><br /></span></div>
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Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-38729230.post-16507104832488355312011-08-18T06:02:00.000-07:002011-08-18T06:04:09.140-07:00<div style="text-align: center;"><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhx05zGHxH1qi7QIXgstr081fYEKH4a2-NM1l-NK5d0pnY5y0hEOB-XC0ZcBBeBLRIAHUmQCZx9InmMU8LfC2gVb0skYX6a2jaM8eNsRgINR_cPzzEmf5z8hndvsv7eGfwW_rC4/s1600/electric+L111.jpg"><img style="display:block; margin:0px auto 10px; text-align:center;cursor:pointer; cursor:hand;width: 400px; height: 386px;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhx05zGHxH1qi7QIXgstr081fYEKH4a2-NM1l-NK5d0pnY5y0hEOB-XC0ZcBBeBLRIAHUmQCZx9InmMU8LfC2gVb0skYX6a2jaM8eNsRgINR_cPzzEmf5z8hndvsv7eGfwW_rC4/s400/electric+L111.jpg" alt="" id="BLOGGER_PHOTO_ID_5642180829684496082" border="0" /></a><span style="font-weight: bold;font-size:130%;" ><span style="font-family: trebuchet ms;">Newest converted electric vehicle</span></span>
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<br />Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-38729230.post-54419947948223252572011-03-12T13:47:00.001-08:002011-03-12T13:51:47.619-08:00New Project<a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgbCwntNRSINM5gk8n0b9Ug_UYyczqe_WAd1zVfrHkKy2v77Lgl1cMXO60C15GBBQAZUuYLUn68x7aptFEVBuyXVAMeCoOU_6bNjgbTMIyL1apLQ0N4VamX8y6da6dVymCYn6ka/s1600/L111+photo.jpg"><img style="display: block; margin: 0px auto 10px; text-align: center; cursor: pointer; width: 180px; height: 108px;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgbCwntNRSINM5gk8n0b9Ug_UYyczqe_WAd1zVfrHkKy2v77Lgl1cMXO60C15GBBQAZUuYLUn68x7aptFEVBuyXVAMeCoOU_6bNjgbTMIyL1apLQ0N4VamX8y6da6dVymCYn6ka/s320/L111+photo.jpg" alt="" id="BLOGGER_PHOTO_ID_5583314308833544834" border="0" /></a><span style="font-family:trebuchet ms;">I'm starting a new project: Converting my John Deere L111 Riding Lawn Tractor to All-Electric, 100% battery power.</span> <span style="font-family:trebuchet ms;">Follow at: </span><a style="font-family: trebuchet ms;" href="http://electrictractor.blogspot.com/">http://ElectricTractor.blogspot.com</a>Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-38729230.post-45429069510673635082010-05-16T17:16:00.001-07:002010-05-16T17:21:06.014-07:00Turning Sunlight into Road Miles<div style="text-align: center;"><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4kVucAmrc6cwJHvh71laRWh9ggjfmwx0jWprMXGFeJqdb_obD-5vmiuGwkandNnSoyqzM8s1hGc5GVUaVZ1JJ3lFYuw6AOY_ItMJLJxRg-IG0-_MSXP6peIfewEz2SO6SNyYO/s1600/solar+charging.jpg"><img style="display: block; margin: 0px auto 10px; text-align: center; cursor: pointer; width: 400px; height: 310px;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4kVucAmrc6cwJHvh71laRWh9ggjfmwx0jWprMXGFeJqdb_obD-5vmiuGwkandNnSoyqzM8s1hGc5GVUaVZ1JJ3lFYuw6AOY_ItMJLJxRg-IG0-_MSXP6peIfewEz2SO6SNyYO/s400/solar+charging.jpg" alt="" id="BLOGGER_PHOTO_ID_5472026516501022642" border="0" /></a><span style="font-family: trebuchet ms;">Last Saturday, I taught a class in building a solar array. After the class was over I thought, "Why not put that project to good use." Hence: Here is the 875 watt solar array re-charging the batteries in my electric VW. What more can you ask for ... Sunlight to Road miles!</span><br /></div>Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-38729230.post-67986139709280118742010-04-20T21:12:00.001-07:002010-04-20T21:43:06.657-07:00Nice Driving Weather ... Finally!<a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhV26j1GmJ2mIGr_wHMWs1x_HOObauUKgFmoyT30dfDJG3FM5oDx51G1o__VYglTk0KTVpYyw1pbk-1Tm-APyJ9fV3PFDTX52YyFGxMqqz4LDT_e-0RhTsjgx9MkcuulsDbLmpA/s1600/driving+again+2010.jpg"><img style="display: block; margin: 0px auto 10px; text-align: center; cursor: pointer; width: 400px; height: 261px;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhV26j1GmJ2mIGr_wHMWs1x_HOObauUKgFmoyT30dfDJG3FM5oDx51G1o__VYglTk0KTVpYyw1pbk-1Tm-APyJ9fV3PFDTX52YyFGxMqqz4LDT_e-0RhTsjgx9MkcuulsDbLmpA/s400/driving+again+2010.jpg" alt="" id="BLOGGER_PHOTO_ID_5462439102122506290" border="0" /></a><span style="font-family: trebuchet ms;">Driving again: Beautiful 70+</span> weather today. It was a good day to take the "Electric Jet" to the barber shop so the driver could get a "spring trim."<br /><br />Photo shows recharging on the helicopter landing pad. Whenever possible I open the hood for recharging so as to let the gasses escape. This prevents rust from forming in the battery compartment.<br /><br />Sadly, due to the big John Deere tractor Upgrade project/business, I never got any of the planned winter-downtime improvements done. Hopefully, I'll get to them soon. ("Soon" being quite undefined.)<br /><br />Adding to the prior items, I've acquired a LINK-10 ("E-Meter") that needs to be installed. This is a very handy gadget which will monitor and log all battery functions.<br /><br />FIRST on the list is headlight re-wiring! I drove home last night with headlights about as powerful as a 1950 Schwinn bicycle! The problem is typical undersized VW wiring, plus bad grounds. When I get done, I think it will light up the road like a 747 on short final approach!<br /><br />The original <span style="font-weight: bold; font-style: italic;">US Battery</span> battery pack is doing better than expected. I figured I would have to replace the pack first thing this year, since this is the fourth year on the pack. So far, it's still chugging well after 25 miles, which will get me to Pullman, and back, still with a little reserve to run around in town a bit. (Down from the initial 50 mile range) I haven't actually "pushed it" to see what the actual range is, however I have definitely noticed that the range is increasing as I drive it this year.<br /><br />I plan to add two more 6-volt batteries, using the Electro Automotive under the floor battery box. It looks very well designed, as is all their products.<br /><br />Rob, another Cabbie Converter (http://chaosmgmt.blogspot.com) just installed a lithium-ion pack. I'm watching that carefully and might consider it, if the price is right. Other than being able to extend the vehicle range an amount farther than I usually drive and allow me to spin the wheels and beat most cars to the first stop-light, I really can get along with my faithful non-BMS lead-acid batteries. (Re: Smoking Tires - Pullman is a "Small Town" and too many people know me!)<br /><br />Stay Tuned ...Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-38729230.post-34764978685565430482010-01-10T19:33:00.000-08:002010-01-10T19:48:45.195-08:00Next "Electrifying" Project<div style="text-align: center;font-family:trebuchet ms;"><span style="font-weight: bold; font-family: trebuchet ms;">NEXT PROJECT</span><br /><span style="font-family: trebuchet ms;">How about an Electric, Solar Charged, "Off-Road Monster," Golf Cart?</span><br /><span style="font-family: trebuchet ms;">Yeah ... I think so!</span><br /></div><br /><div style="text-align: center; font-family: trebuchet ms;"><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgr3W85QnKQ8CJ7H3fcEmpTtZPqXOeWCRDNA1TQUYpmvO1Baz-3E8HbkdtA-0gLWxr2I1_MjcgkHhVSspJs6IxuUUzePH4k7nsF18HQ9JitOdQlQnkm8pWU5qUsAjVNH1P-kpQu/s1600-h/golf+cart+2.jpg"><img style="margin: 0px auto 10px; display: block; text-align: center; cursor: pointer; width: 315px; height: 400px;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgr3W85QnKQ8CJ7H3fcEmpTtZPqXOeWCRDNA1TQUYpmvO1Baz-3E8HbkdtA-0gLWxr2I1_MjcgkHhVSspJs6IxuUUzePH4k7nsF18HQ9JitOdQlQnkm8pWU5qUsAjVNH1P-kpQu/s400/golf+cart+2.jpg" alt="" id="BLOGGER_PHOTO_ID_5425320719495552258" border="0" /></a><span style="font-family: trebuchet ms;">Step 1: Install a 6" Lift Kit and cool-looking wheels and tires.</span><br /><br /><div style="text-align: left;"><span style="font-family: trebuchet ms;">The future:</span><br /><br /><ul><li>New Paint Job</li><li>New upholstery that is appropriate for the new paint.</li><li>Headlights</li><li>Add a bunch of chrome</li><li>Convert from gas power to electric power</li><li>Install a solar module on top to keep the running batteries fully charged.</li><li>Oh yes ... Seat Belts!<br /></li></ul></div><br /></div>Unknownnoreply@blogger.com1tag:blogger.com,1999:blog-38729230.post-4820848624329257982009-12-08T21:04:00.000-08:002009-12-08T21:28:00.201-08:00Things Are Heating Up<span style="font-family: trebuchet ms;">Now that Winter is upon us, (-3F tonight) it's time to pull the Electric Jet out of service for winter maintenance. I basically have three projects: Add a heater; Improve headlights; Fix the door and window operation.</span><br /><br /><br /><span style="font-family: trebuchet ms;">Heater: I have mocked up a possible heater setup ... and it seems to work well. Now I have to install in the car.</span><br /><br /><br /><span style="font-family: trebuchet ms;">At first, I planned on installing an electric ceramic heater, as many have done, but decided against that because of potential safety issues. I think hot water will work better.</span><br /><br /><br /><span style="font-family: trebuchet ms;">I bought a small hot water heater tank that is used in the winter as an engine block heater. (eBay) It has a 1000 watt 115vac heater element and will work on 96vdc, just fine. (Tank heaters are available up to 2000 watts.) I used a small 12 vdc hot water pump used in solar hot water systems to circulate the water. (El-Sid pump). Hooking all this in series with a new VW heater core, I proved that it will put out a good supply of hot air.</span><br /><br /><br /><span style="font-family: trebuchet ms;">I will wire it in, in such a manner that I can run the heater on aux. home power for a time before departing, so as to pre-heat the car interior. When I'm ready to depart, I will switch it over to car power.</span><br /><br /><br /><span style="font-family: trebuchet ms;">Before you ask: The whole heater system will require about 1,100 watts of power, when ON. Compare that to the 20,000 watts of power the car uses in normal cruise. This computes out to about an added 5% requirement, which in most cases will not affect power or range to any appreciable amount.</span><br /><br /><br /><span style="font-family: trebuchet ms;">I think this will be a safe system, with minimal amount of controls required. If it starts to overheat, the hot water heater tank has a internal cut-off thermostat switch.</span><br /><br /><br /><span style="font-family: trebuchet ms;">What could be easier?</span>Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-38729230.post-53185311544640534222009-04-04T18:32:00.000-07:002009-04-04T18:49:36.969-07:00What Happens When You Short Out The Pack<span style="font-family:trebuchet ms;">Here is why I always wear gloves and eye protection!<br /><br />Today, I was doing the spring battery maintenance, which consisted of topping off the water and tightening the battery terminal connections. For the tightning, I use a 1/2" box end wrench that is wrapped with electrical tape. The only exposed part is the box end.</span><br /><span style="font-family:trebuchet ms;"></span><br /><span style="font-family:trebuchet ms;">Today, however, I needed an extra wrench and I just grabbed another, unwrapped wrench. Unfortunately, it slipped and shorted across the entire pack of batteries in the rear of the car. This was "only" eight of the sixteen in the car. When it crossed the terminals, it was like a Fourth of July display, with hot molten steel flying in all directions. I can't imagine what would happen if full pack had been shorted.</span><br /><span style="font-family:trebuchet ms;"></span><br /><span style="font-family:trebuchet ms;">In the second picture, you can see chunks of molten steel and tracks across the battery tops where the hot metal rolled across.</span><br /><span style="font-family:trebuchet ms;"></span><br /><span style="font-family:trebuchet ms;">Word to EV builders and owners: BE CAREFUL.<br /><br /><br /></span><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhFgDyeRSQxUV61ybyjhVubQwIBrPVnsoePXmlfCMMFlkDjyZwB44CrAhdS0PNIJOKkhskaT-ZRj2Xe1nWWf6mSiqwJD6QDBiMn_H7CTPgFvIM1X1BaudnBUj5cosvMLTs8LaIf/s1600-h/short+2.jpg"><span style="font-family:trebuchet ms;"><img id="BLOGGER_PHOTO_ID_5321014770316622002" style="DISPLAY: block; MARGIN: 0px auto 10px; WIDTH: 277px; CURSOR: hand; HEIGHT: 400px; TEXT-ALIGN: center" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhFgDyeRSQxUV61ybyjhVubQwIBrPVnsoePXmlfCMMFlkDjyZwB44CrAhdS0PNIJOKkhskaT-ZRj2Xe1nWWf6mSiqwJD6QDBiMn_H7CTPgFvIM1X1BaudnBUj5cosvMLTs8LaIf/s400/short+2.jpg" border="0" /></span></a><span style="font-family:trebuchet ms;"><br /></span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgZS13bGhO1VOey0O7ioG3U-t5ZbTdW75-0CQZ7AieH4hPdrRXAlIgmlbfxdtrj1Jy7JYaarDdOXIjUn_5TYhzVq4LovQVd4PuYH6GrCA0Di2_4dY53f0kliPfajclC2Nx3r88B/s1600-h/short+1.jpg"><span style="font-family:trebuchet ms;"><img id="BLOGGER_PHOTO_ID_5321014769457917586" style="DISPLAY: block; MARGIN: 0px auto 10px; WIDTH: 328px; CURSOR: hand; HEIGHT: 400px; TEXT-ALIGN: center" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgZS13bGhO1VOey0O7ioG3U-t5ZbTdW75-0CQZ7AieH4hPdrRXAlIgmlbfxdtrj1Jy7JYaarDdOXIjUn_5TYhzVq4LovQVd4PuYH6GrCA0Di2_4dY53f0kliPfajclC2Nx3r88B/s400/short+1.jpg" border="0" /></span></a><span style="font-family:trebuchet ms;"><br /><br /></span><div></div>Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-38729230.post-43502976153162640742009-01-24T15:08:00.000-08:002009-01-24T15:29:23.225-08:00Possible Design DefectIn my opinion there is a design defect in the Electro Automotive VW wiring scheme:<br /><br />I have lost two 12 vdc vehicle aux. batteries. Last week, the second aux. battery ended up fully discharged … and frozen. (The temp in my barn has been in the 0-25 deg. F range.)<br /><br />Remember from my last blog entry, I discussed long maintenance charges?<br /><br />Here's the problem:<br /><br />Whenever external power is plugged into the car outlet for charging, the 12vdc fan is activated to ventilate the rear battery box. The fan is powered from the aux. battery During this time, there is no recharging of the aux. battery. It's the same as leaving the car lights ON, when leaving the car ... albeit, with a much lower current draw.<br /><br />I frequently plug in my charger in the afternoon, upon return home, and leave it ON all night, as my PFC-20, turns OFF at the appropriate time. It seemed like there was no downside to this technique. Several times, when the power was plugged in for extended times, even with the charger OFF, the aux. battery became fully discharged, eventually resulting in my buying a new battery.<br /><br />During the worst of this winter, my car stays in the barn. In order to preserve the batteries, I use my PFC 20 to frequently charge the batteries. Last week, I left the charger on for 24 hours, in 10 deg. weather, with the charger set at the appropriate float voltage. When I checked later, I discovered the fan stopped, the aux, battery dead ... and frozen! I now have to buy another new battery.<br /><br />I think it's a poor design to run the battery box ventilator with a 12vdc fan, powered from a source that isn't kept charged. I plan on replacing the fan, ASAP, with a 120vac fan that runs from external house power whenever the vehicle is plugged in.<br /><br />If this situation applies to you, I suggest you replace the 12vdc fan with a 125vac fan, wired in appropriately.<br /><br />Just my opinion.Unknownnoreply@blogger.com4tag:blogger.com,1999:blog-38729230.post-64960657751820799802009-01-09T13:01:00.000-08:002009-01-09T13:17:13.678-08:00Winter Upkeep: Part 2<span style="font-family:trebuchet ms;">In battery lore, there are two critical numbers: The first is the "Charge to" voltage, sometimes referred to as the "Acceptance" voltage. This the the voltage the pack should be charged to after usage. The second number is the "float" voltage. This is the voltage the pack should be held to when not being used i.e., the pack should float along at this voltage when idle. Both voltages are computed, based upon battery type and battery temperatures, among other things.</span><br /><span style="font-family:trebuchet ms;"></span><br /><span style="font-family:trebuchet ms;">In the case of my pack, the float voltage at the 30-35 deg.F, is 105.95 - 106.25 volts. Using a thermometer, my PFC20 charger and a lab quality digital voltmeter, I am going to float the pack for a day, or so, to do a rather lengthy "equalizing balance."</span><br /><span style="font-family:trebuchet ms;"></span><br /><span style="font-family:trebuchet ms;"></span><br /><div align="center"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhNq3rhxSbfANo3jTS7L0iCbl1AIu7kdI7I4xW6GIIqEgEnzvCEw4dRiCqYqNrWIuhYlAwyBnIcyjBDMfE_ROvrJpwc1-UM-HTXZcCqFcCcgzsadfnmXJdJLSJvFp31psMCsUcN/s1600-h/Float+voltage.jpg"><span style="font-family:trebuchet ms;"><img id="BLOGGER_PHOTO_ID_5289402756420459906" style="DISPLAY: block; MARGIN: 0px auto 10px; WIDTH: 400px; CURSOR: hand; HEIGHT: 232px; TEXT-ALIGN: center" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhNq3rhxSbfANo3jTS7L0iCbl1AIu7kdI7I4xW6GIIqEgEnzvCEw4dRiCqYqNrWIuhYlAwyBnIcyjBDMfE_ROvrJpwc1-UM-HTXZcCqFcCcgzsadfnmXJdJLSJvFp31psMCsUcN/s400/Float+voltage.jpg" border="0" /></span></a><span style="font-family:trebuchet ms;"><em>(CLICK photo for a larger image)</em></span><br /></div><span style="font-family:trebuchet ms;"></span>Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-38729230.post-21283929818010395132009-01-04T19:49:00.000-08:002009-01-04T20:07:27.991-08:00Winter Upkeep<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjIJ7hCqpnkCP1dd8-QqSqH-ST_haCV5GK_A4cY4cMX14nla6wbTrpsQiPaBasf6Ot0X3B0yv6or2c6MXNUQHrazttUSy747eWn-PzyJXInr7y0DgWARdWp_bCrI8Mz1-SpXt0K/s1600-h/snowblower.jpg"><img id="BLOGGER_PHOTO_ID_5287652461835096354" style="DISPLAY: block; MARGIN: 0px auto 10px; WIDTH: 400px; CURSOR: hand; HEIGHT: 279px; TEXT-ALIGN: center" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjIJ7hCqpnkCP1dd8-QqSqH-ST_haCV5GK_A4cY4cMX14nla6wbTrpsQiPaBasf6Ot0X3B0yv6or2c6MXNUQHrazttUSy747eWn-PzyJXInr7y0DgWARdWp_bCrI8Mz1-SpXt0K/s400/snowblower.jpg" border="0" /></a><br /><div></div><br /><p>It's not the best electric vehicle weather ... especially considering that we're having a hard time even getting our Volvo XC90 (4-wheel drive!) out to the county road.</p><p>So, for the time being the VW is staying in the unheated garage/barn. While there, I'm being very careful to keep the batteries fully charged. I have a chart from the battery manufacturer (U S Battery) that states the "charge to" and "float" voltages. Using my HP precision digital voltmeter to monitor my Manzanita Micro PFC20 charger, I periodically do a charge to the "charge to" voltage, followed by a 30-min equalizing charge. This is the same technique I used last year. Even though the vehicle sat for about three months in temperatures as low as -10 degF, when I reactivated the VW, last spring, I saw virtually no loss from the batteries! I hope I can say the same thing this spring!</p><p>As far as the video, I mentioned in an earlier blog, that will have to wait until spring. I will get it done ... promise! </p>Unknownnoreply@blogger.com2tag:blogger.com,1999:blog-38729230.post-73675115978425188972008-12-08T10:35:00.000-08:002008-12-08T11:48:56.100-08:00No Heat - No Problem<span style="font-family:trebuchet ms;">For some time now, I have been "getting ready" to take on the task of adding a heater to the Cabbie. There are, by my count, about three reasonable possibilities:</span><br /><br /><span style="font-family:trebuchet ms;"></span><br /><br /><span style="font-family:trebuchet ms;"><strong>Option One:</strong> Replace the old hot water heater with an electric ceramic element. The ceramic element would be installed in the original VW heater box, along with the appropriate electric controls to run it. This would make a nice professional installation and the heater would function much like the original VW unit. I actually have all the parts gathered together ... I just haven't gotten around to it.</span><br /><br /><span style="font-family:trebuchet ms;"></span><br /><br /><span style="font-family:trebuchet ms;"><strong>Option Two:</strong> I have read about several heater installations involving conventional hair driers. Since the hair drier really doesn't care if it's plugged into the household 115 vac outlet or my 98-volt DC battery pack, the hair drier will run just fine (maybe even better!) and put out copious amounts of hot air. Some builders have stuck the end of the drier into one of the car's air vent lines and simply switched it ON/OFF manually. An advantage of the hair drier is it can be pointed directly at the windshield for fast defrost or defog. I'm thinking: If I constructed a small metal box as a "docking station" to hold the hair drier, the box could direct the warm air from the drier into the cabin area. Then if I needed defrosting or defogging, I just lift the hair drier from it's "docking station", then return it when the windshield has been cleared. I actually am beginning to favor this approach ... to the point that I will probably give it a try ... after I get tired of Option Three!</span><br /><br /><span style="font-family:trebuchet ms;"></span><br /><br /><span style="font-family:trebuchet ms;"><strong>Option Three:</strong> Do nothing! I've been driving quite a bit in 25-28 deg. F, weather with no heater and it really isn't all that bad! With a warm coat, light gloves and a warm hat, I don't mind it that much during my nine-mile work commute. After all, it would usually take three or four miles for a conventional car to warm up, so you would dress warmly, anyway.<br /><br /></span><span style="font-family:trebuchet ms;"><span style="font-family:trebuchet ms;"></span><br /><br /><span style="font-family:trebuchet ms;"><strong>BOTTOM LINE:</strong> Don't get too worked up over how to get heat into your conversion. Just make sure all the holes in the vehicle firewall are plugged. I had one pretty good sized hole where the old heater assembly came out and that let in a lot of cold air, while driving. Once the air leaks were plugged, as I mentioned, "It really isn't all that bad."</span><br /><br /><span style="font-family:trebuchet ms;"></span><br /><br /><span style="font-family:trebuchet ms;"><strong>HINT:</strong> If I have the chance, I "pre-heat" the cabin, using a small 115 vac ceramic type heater. (Yes, the one that I planned on taking apart to permanently install in the car.) If I know I'll be driving in 15-30 minutes, I put the heater on the floor of the passenger side, being EXTREMELY careful that it isn't in any position to overheat any part of the car (Like in: Catch on fire!) The warmed up car feels pretty good and the heat will persist for several miles.</span><br /><br /><img id="BLOGGER_PHOTO_ID_5277503677038065474" style="DISPLAY: block; MARGIN: 0px auto 10px; WIDTH: 164px; CURSOR: hand; HEIGHT: 176px; TEXT-ALIGN: center" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjEI_RnhCPjSrZl5hQWEBe4gODvkjxqhyphenhyphenQgCxK9r4AwwxbLLehfkxW5YkmlCODiJRao7s5xIFfWPpt7Du4M0MbR8aaijAC8ULIwwZnicr3LTEdbjYa0vWYRFNkX88qoKlGVtDLs/s320/vw+heater.jpg" border="0" /><br /><br /></span>Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-38729230.post-45362873961906355382008-10-12T20:16:00.001-07:002008-10-12T20:18:35.894-07:00What it like to drive an EV<span style="font-family:trebuchet ms;">Stay Tuned:</span><br /><span style="font-family:trebuchet ms;"></span><br /><span style="font-family:trebuchet ms;">Before too long I'll grab the video camera and take you on an informative tour and ride in my "Electric VW."</span>Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-38729230.post-54133743406534523122008-09-01T20:31:00.000-07:002008-09-01T20:53:35.487-07:00Road Report<span style="font-family:trebuchet ms;">It's been about two weeks since I have the car back on the road after the front end rebuild.</span><br /><span style="font-family:trebuchet ms;"></span><br /><span style="font-family:trebuchet ms;">It drives almost like a new car. I am particularily impressed with the Bilstein shocks. The ride is "Euro-Firm." I like it: It reminds me of my last Audi i.e., great road feel and very positive steering. It also helped to get the lower anti-roll bar reinstalled, along with the upper strut tower support fixture. (I have to ask myself: "Why didn't I do this sooner?")</span><br /><span style="font-family:trebuchet ms;"></span><br /><span style="font-family:trebuchet ms;">Next project will be headlights and heater.</span><br /><span style="font-family:trebuchet ms;"></span><br /><span style="font-family:trebuchet ms;"></span>Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-38729230.post-81646068099676300472008-08-17T21:55:00.000-07:002008-08-17T22:28:10.020-07:00Work-In-Progress<div align="center"><span style="font-family:trebuchet ms;"><br /></span></div><div align="left"><span style="font-family:trebuchet ms;">As of today, I have one side completed. I would have been done, but discovered yesterday that one upper strut bearing plate was worn beyond limits. No one in town carries the part so it was ordered thru Schuck's Auto Parts. It will be here Monday AM. (I endorse Schuck's. They are very responsive to parts orders.)</span></div><div align="center"><span style="font-family:trebuchet ms;"></span> </div><p align="center"><span style="font-family:trebuchet ms;"><img id="BLOGGER_PHOTO_ID_5235722585102684498" style="DISPLAY: block; MARGIN: 0px auto 10px; CURSOR: hand; TEXT-ALIGN: center" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjkkwWweoqeLy9yQKH9i8BiXZwAP6FLCh1X0JzBd_oq-6as-tGmajUaCqwIgnmjBsWEPa4J-1UQfNW54TDYgIeEVyMhmohehENQSqdl7zDRh74PjV8ZcGYs_InbU_uZ8VgjG3h8/s320/bilstein.jpg" border="0" />A Bilstein performance strut assembly ... The Best!<br /></span></p><p align="center"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj1sP-blM6HD2dsTKaZH-VglFSfWjuW2HxCtE4k5ePDqKuw7zUMvBou-UoERXsWbv8yhA-bcr2M31wTibsV_kOimIlUDpS8GUs407a-xDUhf9YDvZsGuVYUmFrOEY-wFWaO782n/s1600-h/driveshaft.jpg"><span style="font-family:trebuchet ms;"><img id="BLOGGER_PHOTO_ID_5235720912753742530" style="DISPLAY: block; MARGIN: 0px auto 10px; CURSOR: hand; TEXT-ALIGN: center" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj1sP-blM6HD2dsTKaZH-VglFSfWjuW2HxCtE4k5ePDqKuw7zUMvBou-UoERXsWbv8yhA-bcr2M31wTibsV_kOimIlUDpS8GUs407a-xDUhf9YDvZsGuVYUmFrOEY-wFWaO782n/s320/driveshaft.jpg" border="0" /></span></a><span style="font-family:trebuchet ms;"> New driveshaft/CV joint assembly. Both left and right were replaced.</span></p><p align="center"><span style="font-family:trebuchet ms;"></span> </p><p align="left"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjY9VzGoaKKyLSfyME1sJsxKLF_bnv9lLSXcnURzjT6cj-sVopGVWTfcLAlpBhVGPYP4UBIq3V4ToPMs7nt3Z4zymriOsBDG1jku3z4Fq0Xh7JaL9oXu0nViPVqnH_mFqkgz6BU/s1600-h/stab+bar.jpg"><span style="font-family:trebuchet ms;"><img id="BLOGGER_PHOTO_ID_5235720924868950754" style="DISPLAY: block; MARGIN: 0px auto 10px; CURSOR: hand; TEXT-ALIGN: center" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjY9VzGoaKKyLSfyME1sJsxKLF_bnv9lLSXcnURzjT6cj-sVopGVWTfcLAlpBhVGPYP4UBIq3V4ToPMs7nt3Z4zymriOsBDG1jku3z4Fq0Xh7JaL9oXu0nViPVqnH_mFqkgz6BU/s320/stab+bar.jpg" border="0" /></span></a><span style="font-family:trebuchet ms;">Upon initial build of the car, I did not attach the upper stabilizer bar because it interferred with the mounting plates for the DC/DC converter, the main contactor and the throttle pot. I trimmed down the mounting plates and now the bar fits. (I put a lot of work into getting a great paint job on the bar.)</span></p><p align="center"><span style="font-family:trebuchet ms;"><br /></span></p><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbN17IKosOMpvCJoChN9GWjHqJAzMLQy5vOy2diPwq10mENRTWemVKaG7ZVvkiEIYMS22x2YRGPzxMwIEMOyZkYhkfcpYFyjKE4cxv7sCK2QmBuBPGgT-p_t5aIisTV-fF3VTF/s1600-h/strut.jpg"><span style="font-family:trebuchet ms;"><img id="BLOGGER_PHOTO_ID_5235720928561838514" style="DISPLAY: block; MARGIN: 0px auto 10px; CURSOR: hand; TEXT-ALIGN: center" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbN17IKosOMpvCJoChN9GWjHqJAzMLQy5vOy2diPwq10mENRTWemVKaG7ZVvkiEIYMS22x2YRGPzxMwIEMOyZkYhkfcpYFyjKE4cxv7sCK2QmBuBPGgT-p_t5aIisTV-fF3VTF/s320/strut.jpg" border="0" /></span></a><span style="font-family:trebuchet ms;"> Here is a pix of the strut assembly installed in the right side of the car. The springs are not stock, but custom wound units designed to handle the added battery weight AND lower the car about 1-1/2" (38 mm)</span></p><p><span style="font-family:trebuchet ms;"><br /></span> </p><div align="center"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg5UZJLjvRbvo9a0DTojEHLzsDvWiENhC2oDOI4kyZgn3STUyrBJ2E5EK3vTlPRdMb_HvS5csD0wwaEx8w7u_f_xiTHHvA5hrN46EXSUrO9aTNybGQvvER5vJ8m2GU5OlQHAeMY/s1600-h/ball+joint.jpg"><span style="font-family:trebuchet ms;"><img id="BLOGGER_PHOTO_ID_5235719949552798578" style="DISPLAY: block; MARGIN: 0px auto 10px; CURSOR: hand; TEXT-ALIGN: center" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg5UZJLjvRbvo9a0DTojEHLzsDvWiENhC2oDOI4kyZgn3STUyrBJ2E5EK3vTlPRdMb_HvS5csD0wwaEx8w7u_f_xiTHHvA5hrN46EXSUrO9aTNybGQvvER5vJ8m2GU5OlQHAeMY/s320/ball+joint.jpg" border="0" /></span></a><span style="font-family:trebuchet ms;"> A new ball joint.<br /><br /><br /></span><br /></div>Unknownnoreply@blogger.com2tag:blogger.com,1999:blog-38729230.post-82761236318747598332008-08-02T18:49:00.000-07:002008-08-02T18:51:49.023-07:00Time-Out<span style="font-family:trebuchet ms;">The V-Dub is down for a little maintenance. It has been very reliable transportation for me for over 3000 miles, since the conversion was completed almost exactly one year ago.</span><br /><span style="font-family:trebuchet ms;"></span><br /><span style="font-family:trebuchet ms;">Last night, while driving to town, I heard a very distinctive "grinding" sound. I had a very good idea what it was: The CV joints. I knew they needed replacing, even when I first started to drive the car after conversion, last year. In fact, I have had the replacement drive shafts/CV joints on hand for several months, waiting until "I felt like" replacing them. I now "feel like it!" Today, I started the disassembly of the front end and will do the following repairs:</span><br /><span style="font-family:trebuchet ms;"></span><br /><span style="font-family:trebuchet ms;"> * Replace both drive shafts and CV joints. (Interesting note: The shafts I have had for several months are the wrong ones! Fortunately, I have the original receipt and can exchange for the correct ones.)</span><br /><span style="font-family:trebuchet ms;"></span><br /><span style="font-family:trebuchet ms;">* I discovered that the wheel bearing on the left-front wheel was totally worn out. I'll replace that, along with the right-front, just as a preventing measure.</span><br /><span style="font-family:trebuchet ms;"></span><br /><span style="font-family:trebuchet ms;">* The right-front steering tie-rod end will be replaced. (It was actually OK, but got a little "banged-up" during removal.)</span><br /><span style="font-family:trebuchet ms;"></span><br /><span style="font-family:trebuchet ms;">* Both front strut cartridges (shock absorbers) will be replaced. I bought new ones when I did the conversion, but they failed almost immediately. (That's what you get for trying to save a buck ... even though they were advertised as "performance.")</span><br /><span style="font-family:trebuchet ms;"></span><br /><span style="font-family:trebuchet ms;">* I have had a tachometer adapter for almost a year, but never installed it because it takes a little drilling into the transmission case. I'll get that done this time.</span><br /><span style="font-family:trebuchet ms;"></span><br /><span style="font-family:trebuchet ms;">* Since I do a lot of driving at night, I need to do some work on the headlights. The wiring is old, resulting in less than optimum light output. They also need to be re-aimed.</span><br /><span style="font-family:trebuchet ms;"></span><br /><span style="font-family:trebuchet ms;">That's probably enough work for this cycle. This winter, I'll catch up on a few more improvements/repairs. The major deferred project is a heater!</span><br /><span style="font-family:trebuchet ms;"></span><br /><span style="font-family:trebuchet ms;">Watch this blog for photos and updates as the work progresses.</span>Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-38729230.post-63200015518612477342008-06-01T19:03:00.000-07:002008-11-13T11:47:14.540-08:00I'm Getting A Charge Out Of You<div align="center"><span style="font-family:trebuchet ms;"></span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhmTr1yosi8POf2-V-YeAxisaxiR2Ad8txdMAKw0Fs0z-fX4Ke-LCMlypfmTFmXjPvQp3w9MTICZo5l7LV3okoW2e0jV8bs1EozWz13qhMf4G_F9XENujsKo918fHZdCrJCLIoj/s1600-h/pfc20.jpg"><img id="BLOGGER_PHOTO_ID_5207104762385184082" style="DISPLAY: block; MARGIN: 0px auto 10px; CURSOR: hand; TEXT-ALIGN: center" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhmTr1yosi8POf2-V-YeAxisaxiR2Ad8txdMAKw0Fs0z-fX4Ke-LCMlypfmTFmXjPvQp3w9MTICZo5l7LV3okoW2e0jV8bs1EozWz13qhMf4G_F9XENujsKo918fHZdCrJCLIoj/s320/pfc20.jpg" border="0" /></a><span style="font-family:trebuchet ms;">This is the Manzanita Micro PFC-20 Charger that I have installed in the truck of the VW. The "AMPS" control sets the charging current. I have marked two positions: 15 AMPS (for charging from a normal 120V household outlet) and a 20 AMP position, which it is currently set at. (I have a dedicated 20 AMP circuit in the barn.) If I used the 20 AMP position for "away from home" charging, I would probably trip the circuit breaker ... NOT a good way to impress friends and neighbors!<br /></span><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhFj-CMzSGaSRz3VP0DS11R4eykjcE32qM8VVk7DTyCW1JSJgnHMdFkMbNolFzrvQMGmuUZOXNANxM2IWq2bJdqEXCZw-f9c5HIOAYW989PgA9_VUi_3dD46QCMuEYR4-jemga0/s1600-h/timer+panel.jpg"><img id="BLOGGER_PHOTO_ID_5207104770975118690" style="DISPLAY: block; MARGIN: 0px auto 10px; CURSOR: hand; TEXT-ALIGN: center" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhFj-CMzSGaSRz3VP0DS11R4eykjcE32qM8VVk7DTyCW1JSJgnHMdFkMbNolFzrvQMGmuUZOXNANxM2IWq2bJdqEXCZw-f9c5HIOAYW989PgA9_VUi_3dD46QCMuEYR4-jemga0/s320/timer+panel.jpg" border="0" /></a>These are the controls for adjusting the time the charger "floats" the battery pack after charging. This is to balance the sixteen batteries in the pack.</div><div align="center">The left arrow points to the rotary switch that lets you "guess" what the balance/float time is. It is a 16-position rotary switch with no hint as to timing except to state that the "three o'clock position" is zero time ... it's kind of a "try it and see" approach. (This could be improved.) This is why I'm using the recording chart device to monitor the times.</div><div align="center">The right row of switches (installed upside-down ... intentionally, I guess for assembly convenience) selects the various charge/float options. The #1 switch ON, as I have selected, selects the option for the balance/float to start as soon as the charger senses the pack has reached the selected charge voltage.<br /></div><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDYXc0dTM8Z8Po6Cf-x-Mv8-pX8gFKPcbNGjM8dksGdxwsVoUvuccTge4NrLi0LOO4f-Nmbn-WsuhXYgpE_04c6HTLu94lP9tD0iYbOFF8lQ4YrHScLh6qGKLCZFHkfrnXclHo/s1600-h/recorder.jpg"><img id="BLOGGER_PHOTO_ID_5207104770975118706" style="DISPLAY: block; MARGIN: 0px auto 10px; CURSOR: hand; TEXT-ALIGN: center" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDYXc0dTM8Z8Po6Cf-x-Mv8-pX8gFKPcbNGjM8dksGdxwsVoUvuccTge4NrLi0LOO4f-Nmbn-WsuhXYgpE_04c6HTLu94lP9tD0iYbOFF8lQ4YrHScLh6qGKLCZFHkfrnXclHo/s320/recorder.jpg" border="0" /></a> A vintage Omega chart recorder that I bought on eBay, several years ago. This is the first real application that I have used it in. Works great!<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjhNCLoS5ONdDa5S2ug-r678wb59pw8xJV2xZuJmaSuXoNVNeBsCYawNHNgIYN14DMdUUUCt3E3pGfH3aRfvv4jXA3is_o8a0WFeiGOnYZDS-JlGglccKReQ3dn26_axtchP0Us/s1600-h/chart.jpg"><img id="BLOGGER_PHOTO_ID_5207104775270086018" style="DISPLAY: block; MARGIN: 0px auto 10px; CURSOR: hand; TEXT-ALIGN: center" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjhNCLoS5ONdDa5S2ug-r678wb59pw8xJV2xZuJmaSuXoNVNeBsCYawNHNgIYN14DMdUUUCt3E3pGfH3aRfvv4jXA3is_o8a0WFeiGOnYZDS-JlGglccKReQ3dn26_axtchP0Us/s320/chart.jpg" border="0" /></a> Here is the latest recording that I made after after an eighteen mile trip to Pullman and back. You can see that the charge time was 3.5 hours, followed by an approximate one hour very low power balance/float.</p><p align="center">With the current cost of electricity here, the total trip cost would have been approximately TWENTY CENTS! I say: "Would have been," because our solar electric system is currently generating MORE power than it takes to recharge the car. We get free "gas" and what's left over, we sell back to the power company! What's better than that?<br />See -> <a href="http://rjrenergy.blogspot.com/">http://rjrenergy.blogspot.com</a><br /></p><p align="center">(CLICK pictures for a larger image)<br /></p>Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-38729230.post-91181351816000285772008-04-27T14:13:00.000-07:002008-11-13T11:47:14.626-08:00Free Ticket To Ride<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgmCKU_-HvjkFltjfLc6kQylyFHH-O_8NmNIcnJIF8apVH4dfo3Z5OU979ysGWkLNiHsbaPKCMv3NVXae6g97_H3tTU1KwgmqiXL84g8U_uE-Jtfkh6MAmQaMS0D2rDSSUI-UCr/s1600-h/car+and+panels.jpg"><img id="BLOGGER_PHOTO_ID_5194037706427266818" style="DISPLAY: block; MARGIN: 0px auto 10px; CURSOR: hand; TEXT-ALIGN: center" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgmCKU_-HvjkFltjfLc6kQylyFHH-O_8NmNIcnJIF8apVH4dfo3Z5OU979ysGWkLNiHsbaPKCMv3NVXae6g97_H3tTU1KwgmqiXL84g8U_uE-Jtfkh6MAmQaMS0D2rDSSUI-UCr/s400/car+and+panels.jpg" border="0" /></a><br /><div align="center"><div align="center"><span style="font-family:trebuchet ms;"><strong>What's better than an electric convertible ride on a warm spring day?</strong></span></div><br /><div><span style="font-family:trebuchet ms;"><strong>What IS better is when the cool ride is powered by energy from the sun.</strong></span></div></div>Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-38729230.post-89140653344834230552008-03-09T20:23:00.000-07:002008-11-13T11:47:14.849-08:00Vacuum Brakes Revisted<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEigkyG4wv4jcMqd3IkV9vZHsxkfgcp8-FuQz9OxN02-sDEecEr771kRLVhgdi1eIZHdD-DIfXowOKv6Zn487r9rdVxAymyllPe8StMqDf4ngdvW80xAUNSoM3Ui4o1DpCbiTNuw/s1600-h/new+vacuum+switch.jpg"><img id="BLOGGER_PHOTO_ID_5175954718022543410" style="DISPLAY: block; MARGIN: 0px auto 10px; CURSOR: hand; TEXT-ALIGN: center" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEigkyG4wv4jcMqd3IkV9vZHsxkfgcp8-FuQz9OxN02-sDEecEr771kRLVhgdi1eIZHdD-DIfXowOKv6Zn487r9rdVxAymyllPe8StMqDf4ngdvW80xAUNSoM3Ui4o1DpCbiTNuw/s320/new+vacuum+switch.jpg" border="0" /></a><br /><div><span style="font-family:trebuchet ms;">March 5, 2008</span></div><br /><div><span style="font-family:trebuchet ms;"></span></div><br /><div><span style="font-family:trebuchet ms;">The weather is finally improving and it's actually getting up to 50 deg. (f) during the day. We still have snow laying around in the shaded areas, but it's about gone. Even the fields are starting to green up.</span></div><br /><div><span style="font-family:trebuchet ms;"></span></div><div><span style="font-family:trebuchet ms;">I'm starting to drive the car again, so I decided I better upgrade and reactivate the power brake system. It's not too bad driving with no brake booster, but I think it would be hard to lock up a wheel in an emergency stop. Also, since I'm letting others drive it occasionally, it's sort of a safety issue.</span></div><br /><div><span style="font-family:trebuchet ms;"></span></div><br /><div><span style="font-family:trebuchet ms;">What I did was replace the vacuum switch (the switch that starts and stops the vacuum pump) with a much better switch from EV Parts. It's adjustable. Next, at the suggestion of several members on the EVDL (Electric Vehicle Discussion List) I put a "surge protector" in series with the vacuum pump motor. (The protector is a ten ohm thermistor.) What the thermistor does is cause the vacuum pump to do a "soft start," which is much more "gentlemanly like."</span></div><br /><div><span style="font-family:trebuchet ms;"></span></div><br /><div><span style="font-family:trebuchet ms;">The system is working good and is now virtually unobtrusive ... and it hold vacuum quite well.</span></div><br /><div><span style="font-family:trebuchet ms;"></span></div><br /><div></div>Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-38729230.post-63026149452517179872008-01-09T12:50:00.000-08:002008-11-13T11:47:15.066-08:00UPDATE: January 9, 2008<div align="center"><strong><span style="font-family:Trebuchet MS;font-size:130%;"></span></strong><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiUaxQiP3ViE3xpBtVNRGaKd8HOfcco0EYW-lRahW1GK1qj7KZ2s3-osh-yiRaOwU1p-aT6jn-6Bv53fs7NXi8-1EH8fPhNB6iQDf_NZbYXqPYqrQKM1bGHkb2tDhkf4r3k4v73/s1600-h/S10+snowed+in.jpg"><img id="BLOGGER_PHOTO_ID_5153582395613604946" style="DISPLAY: block; MARGIN: 0px auto 10px; CURSOR: hand; TEXT-ALIGN: center" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiUaxQiP3ViE3xpBtVNRGaKd8HOfcco0EYW-lRahW1GK1qj7KZ2s3-osh-yiRaOwU1p-aT6jn-6Bv53fs7NXi8-1EH8fPhNB6iQDf_NZbYXqPYqrQKM1bGHkb2tDhkf4r3k4v73/s400/S10+snowed+in.jpg" border="0" /></a> <span style="font-family:trebuchet ms;font-size:130%;"><strong>Project Temporarily Suspended!</strong></span></div><div align="center"><strong><span style="font-family:Trebuchet MS;font-size:130%;"></span></strong> </div><div align="left"><span style="font-family:Trebuchet MS;">Two trucks ... I thought there was only one? Well, the second one, the silver one, was a gift! It has no engine, but the body is very nice. Between the two, I should be able to make ONE very nice electric S10.</span></div>Unknownnoreply@blogger.com0