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"SELECTING A VEHICLE FOR CONVERSION"

by Bob Batson of Electric Vehicles of America, Inc. - May 1991

INTRODUCTION

Selecting a vehicle to convert to an Electric Vehicle (EV) can be difficult, or it can be as simple as 1-2-3 :

Define your purpose for the vehicle and the design features required.
Review the vehicles manufactured that meet your requirements.
Select one or two specific vehicles.

STEP 1. DEFINE THE PURPOSE OF THE VEHICLE

This is the major decision. Why do you want an EV? Where will you drive it? How often? With or without passengers! These are the most important questions that must be answered.

My first EV was a VW Bug in 1987. But I wanted more! My second vehicle was only selected after months of analysis to define the objectives to be met. Sport cars (Toyota MR2, Nissan Pulsar, Honda CRX, etc.) were investigated. The Honda CRX is very lightweight; however, it has limited space for locating batteries. My purpose was finally selected: To demonstrate that EVs can be larger vehicles which serve a useful function.

Of course, there remains the design features and other considerations, including:

Front Wheel Drive vs Rear Wheel Drive.

A front wheel drive vehicle has the advantage of being more efficient; which means increased range. However, front wheel drive vehicles typically have smaller engine compartments.

Availability of Spare Parts / Age of Vehicle

I planned on owning my next EV for 10 years, so I wanted parts to be available. Also any vehicle in New England after 10 years is starting to rust.

Manual Transmission

Most EV conversions are manual transmissions because they are more efficient than automatic transmissions and provide greater range, require less motor torque, require no transmission cooler, and are easier to convert.

Power Steering

Power steering is not recommended because of the continuous power required of the battery system.

Power Brakes

Power brakes are a definite advantage as you increase the weight of the vehicle approximately 800-1200 lbs with the EV components. In many cases, this represents an increase of 20-25 percent in the curb weight of the vehicle. Your goal should always be to have a safe vehicle. Power brakes unlike power steering are only an intermittent energy demand. A typical system requires a 12 V vacuum pump, and a vacuum switch.

Weight Capacity and Distribution

As previously stated, converting an existing vehicle to an EV will add 800 -1200 lbs in curb weight. Check the gross weight of the vehicle including the tires presently on the vehicle to see if it is designed for this increase. If the gross vehicle weight of the vehicle is exceeded, then the vehicle frame and braking system may be beyond their design value.

Component Location

You must also consider where the EV components will be located. Where will the batteries be located; they are the bulk of the additional weight. Will the charger be carried on-board or off-board? How will this change in weight distribution affect the vehicles handling?

Finally, the criteria for my EV became:

A vehicle designed for the extra battery weight.
A vehicle that allowed all batteries to be located outside the passenger compartment.
A vehicle that allowed components to be easily replaced for testing new EV components.
A small passenger compartment to limit the heating requirements in winter.

STEP 2. REVIEW VEHICLES MANUFACTURED

Using the criteria that I developed for the purpose of the vehicle, my selection became easier. I found two classes of vehicles that met my criteria: light-weight pickup trucks and Corvettes. I decided on the light-weight pickup truck. This would also prove that EVs can be larger utility vehicles. There are numerous light-weight trucks available, and the used truck market prices used to be reasonable because new trucks were available at $7,000 -$10,000.

If my criteria was different, a different type of vehicle may have been selected. For example, if the most important criteria was acceleration to 60 mph. Then, the selection would be based on a vehicle with minimum weight and a low drag coefficient. In this case, a vehicle similar to the Honda CRX may have been selected.

STEP 3. SELECT ONE OR TWO MANUFACTURERS

It actually gets easier as each decision is made. Here I searched through the available literature ( Consumer Reports, Changing Times, Motor Trend, etc.) that provided detailed information on the weight and features of the different light-weight trucks available.

These trucks varied in weight from 2555 lbs to 2900 lbs for the standard bed model; the long bed models add another 200 lbs. The lowest weight was the Dodge Ram 50 at 2555 lbs and the Toyota at 2565 lbs. Both of these trucks had an excellent reputations.

When I considered light-weight trucks, I evaluated the VW Truck, an oversize Rabbit. It had the advantage of being light-weight (2100 lbs) as well as front wheel drive to minimize drive train losses. It's disadvantage was that it had not been in production for 10 years.

By doing this evaluation, my search was clearly focused. This eliminated time wasted looking at vehicles that did not meet my criteria.

CONCLUSION

In 1990, my second EV conversion was a 1987 Dodge Ram 50 pickup. This truck had a 5-speed overdrive transmission, power brakes, and rear wheel drive. The batteries are beneath the bed of the vehicle and the weight is over the drive wheels. This was the first truck conversion in NE at that time and the solar vehicle crowd laughed at our EV.

At the 1991 SEV conference, we showed this vehicle. Other EVs shown were Geo Metros and Ford Festivas. I remember Rob Wills looking over our truck and stating "This makes sense". And it did. We had the batteries under the bed in order to lower the center of gravity, tilt bed for easy access, and much more.

And now you have every EV company doing pickups. It all started with a Dodge Ram 50 weighing not much more than a Ford Escort.

In conclusion, consider the long term use of your EV. Here is a vehicle that you are going to invest thousands of dollars and approximately 100-200 hours of your time. Don't buy a vehicle just because it is available at a cheap price. You want to enjoy the vehicle and be proud to show it. Consider value not just initial cost.

If you have questions, comments, or have experienced EV safety problems, please contact:

Electric Vehicles of America, Inc.

48 Acton Street

Maynard, MA 01754

(508) 897-9393

(508) 897-6740 FAX

EVAmerica@aol.com

INTRODUCTION TO ELECTRIC VEHICLES OF AMERICA, INC. (EVA)

During the last few years, EVA has established itself as a supplier of quality EV components and an innovator in electric truck conversions. Our first truck was converted to electric in 1990 to demonstrate the capability of larger vehicles as EVs.

Our vehicles clearly represent a design that is well-engineered for safety, reliability, and maintainability. We are proud to say that our design is the safest in the industry with the use of double contactors, inertia switch, Anderson disconnects, and much more.

CUSTOMERS

During the last few years, EVA has provided EV components, conversions, and/or consulting to U.S. Air Force, Braintree Electric, Chicopee Electric Light, Cincinnati Gas Electric, Cleveland Electric, Commonwealth Energy, Elizabethton Electric, General Public Utilities, Nevada Power, Reading Municipal Lighting, Taunton Municipal Lighting, Toledo Edison, and others. Many of these have worked with their local high school in the EV conversion.

In addition, EVA has worked with businesses, high schools, colleges, and individuals across the country and abroad in building their own EVs. In the American Tour de Sol race across New England, our customers have won " Best Lead Acid" EV since 1991, achieving more than 100 miles on a single charge. Our high school customers have won the Mid-Atlantic Challenge and the Phoenix 500!

COMPONENT PACKAGE

With our package, we provide an Installation Manual, schematics, drawings, and the "Safety First" video showing the layout and safety features of our S15 truck. And if you have any questions, we are no further away than your phone.

EVAMERICA NEWSLETTER

EVA also has its own quarterly newsletter "EVAmerica". This newsletter identifies ways to improve the performance of your EV, articles on our customers EVs, EVs for sale, etc. Our newsletter comes with a coupon for a 10 percent discount up to $30 every quarter.

Yes, that's $120 worth of coupons annually. The subscription cost is only $30/year. And with the subscription, you get the "Safety First" video.

Subscribe now and receive your first discount coupon and the "Safety First" video by sending $30 to:

Electric Vehicles of America, Inc.

48 Acton Street

Maynard, MA 01754

In conclusion, we look forward to discussing how EVA can assist you in building an EV to meet your needs.

Bob Batson (EVAmerica@aol.com)

Visit our Home Page at http://www.inc.com/users/evainc.html

Electric Vehicles of America, Inc. (EVA) Tel# 508-897-9393, Fax# 508-897-6740 48 Acton Street, Maynard, MA 01754 USA

Authorized Distributor for Advanced DC Motors, Curtis Controllers, Albright Contactors, and other EV component manufacturers. Free catalog. Largest EV Component supplier in the East Electric cars, trucks, motorcycles, boats, ski-dos, and more.

EVA - " Customer Service is No. 1! "