316 Indexbuying an EV. See purchasing an EVCcable gauge wire, 226Café Electric LLC, 299CAFE (Corporate Average Fuel Economy)standards, 18, 53California Air Resources Board (CARB),10–13, 63–65, 308California Electric Cars, 289California Energy Commission, 308California environment/transportationagencies, 288California Fuel Cell Partnership, 310California regulations, 63–65CALSTART, 58, 60Camissa, Mike, 15Canadian Electric Vehicles, Ltd., 295Canadian Environment IndustryAssociation (CEIA), 311capacitor-start designs, 150car <strong>com</strong>panies, 1, 2, 16, 23, 40car manuals, 130, 236, 303CARB (California Air Resources Board),10–13, 63–65, 308cars. See also automobiles; EVs; vehiclesaerodynamic designs, 104, 108<strong>com</strong>pact, 47as conversions, 81–84, 86, 87converting to electric vehicles, 3–7growth in registrations after WWII,43–44steam engine, 33, 34CEIA (Canadian Environment IndustryAssociation), 311cell voltage, 209Change of Pace vehicles, 52chargers. See battery chargerscharging batteries. See battery chargingcharging connector/plug, 256, 259, 260, 276chassis, 119–131checklist for, 130choosing, 86–87, 95–96cleaning, 237considerations, 86–87conversion process, 89, 234–238draining fluids, 237, 238drivetrain <strong>com</strong>ponents, 112–119, 130,275finding deals, 128–129flowchart, 97late-model vehicles, 96, 129–130manuals for, 130, 236measuring, 237new vs. used, 234–235overview, 119preparing, 237purchasing, 127–131, 234–235purchasing parts for, 236re<strong>com</strong>mendations for, 79removing parts, 237–238rolling resistance, 109, 112, 130streamlined design, 95, 104–109, 108tires, 109–111, 275weight, 86–87, 98–104, 130Chernobyl nuclear accident, 55Ch<strong>ev</strong>ron, 39, 48Ch<strong>ev</strong>y S-10 trucks, 85, 230Chezar, Bart, xviichopper control, 163Chrysler, 48, 51, 215Chrysler, Walter, 40Chrysler Epic van, 62, 63Chrysler TEVan, 62Chrysler/GE, 48Churchill, Winston, 40circuit breaker, 219, 249–250, 263CitiCars, 48, 49city electric vehicle, 76Clean Air Act of 1968, 53Clean Air Transport of North America, 289Clooney, George, 154, 156Cloud Electric Vehicles Battery PoweredSystems, 289clubs, 277–286clutch, 113, 116, 118, 240, 273coal, 38, 43coasting, 273, 274Cocconi, Alan, 171–172coils, 138–139<strong>com</strong>munity-related electric vehicle sites,308–309
Index 317<strong>com</strong>mutator, 138–139<strong>com</strong>ponents. See parts<strong>com</strong>pound DC motors, 145–146Conceptor Industries, 289Concorde Battery Corp., 300conductors, 137, 138connectionsbattery, 194–195checking, 275electrical system, 218, 221, 226–228wiring, 263–265connectors, 192, 193, 226–227, 262Conoco, 39consultants, 288, 293–295contactors, 218–219, 220, 221, 254controllers, 159–176AC, 161, 166–167, 170AC Propulsion Inc., 171–174best options for, 167–170Curtis PMC, 165–166DC, 162–166, 168–170homemade, 165Jones chopper circuit, 162–166, 168off-the-shelf sources for, 299–300overview, 9–10, 159–161performance and, 2–3PWM, 162–166, 168safety features, 160, 168, 173solid-state, 161–167suppliers of, 299–300Tesla, 175ZAPI, 170Zilla, 168–170conventions, 96–98conversion consultants, 293–295conversion kits, 297–298conversion plans, 298conversion professionals, 291–292, 293conversion shops, 77conversions, 229–249. See also building anEV; designadvantages, 75–76, 79–81, 128arranging for help with, 231–232, 238arranging for purchases/deliveries,234arranging for tools, 232batteries. See batteriescars as, 81–84, 86, 87chassis. See chassisconsiderations, 2, 75–81, 85–89consulting services for, 293–295cooling improvements, 266–268costs, 90–93disadvantages, 128early years of, 50, 52“electric” sign, 268–269electrical stage, 234, 246–260examples of, 81–86finding location for, 232finding vehicles for, 79–80labor, 79, 80–81Mazda RX-2, 82–83mechanical stage, 234, 238–246mounting motor, 238–243overview, 229–231painting vehicle, 268–269phases, 234pickup trucks, 85, 87, 229–231planning stage, 231–234plans for, 298Plymouth Arrow, 84Porsche 959, 3, 4, 83post-conversion tasks, 263–269Rolls Royce, 81–82safety issues, 77–78summary of process, 233, 234suppliers, 295–302SUV, 86time required for, 77trial runs, 265van, 81, 82, 87vs. building an EV, 75–76, 128vs. buying an EV, 75–76weight and, 86–87, 98–104, 130converters, 288cooling improvements, 266–268core deposit, 193Corporate Average Fuel Economy (CAFE)standards, 18, 53costs. See also purchasing an EVbatteries, 3–5, 193electricity, 12
- Page 2 and 3:
Build Your OwnElectric Vehicle
- Page 5 and 6:
Copyright © 2009 by The McGraw-Hil
- Page 7 and 8:
For more information about this tit
- Page 9 and 10:
ContentsviiRemember the 30 Percent
- Page 11 and 12:
Contentsix8 Batteries .............
- Page 14 and 15:
xiiContentsChargers ...............
- Page 18 and 19:
xviPrefaceFi g u r e 2 TH!NK City c
- Page 20 and 21:
This page intentionally left blank
- Page 22 and 23:
xxAcknowledgmentscar conversions fo
- Page 24 and 25:
This page intentionally left blank
- Page 26 and 27:
2 Build Your Own Electric Vehicleco
- Page 28 and 29:
4 Build Your Own Electric VehicleFi
- Page 31 and 32:
Chapter 1: Why Electric Vehicles Ar
- Page 33 and 34:
Chapter 1: Why Electric Vehicles Ar
- Page 35 and 36:
Chapter 1: Why Electric Vehicles Ar
- Page 37 and 38:
Chapter 1: Why Electric Vehicles Ar
- Page 39 and 40:
Chapter 1: Why Electric Vehicles Ar
- Page 41 and 42:
Chapter 1: Why Electric Vehicles Ar
- Page 43 and 44:
Chapter 1: Why Electric Vehicles Ar
- Page 45 and 46:
CHAPTER 2Electric VehiclesSave the
- Page 47 and 48:
Chapter 2: Electric Vehicles Save t
- Page 49 and 50:
Chapter 2: Electric Vehicles Save t
- Page 51 and 52:
Chapter 2: Electric Vehicles Save t
- Page 53 and 54:
Chapter 2: Electric Vehicles Save t
- Page 55 and 56:
CHAPTER 3Electric Vehicle History
- Page 58 and 59:
34 Build Your Own Electric Vehiclea
- Page 60 and 61:
36 Build Your Own Electric VehicleF
- Page 62 and 63:
38 Build Your Own Electric Vehiclea
- Page 64 and 65:
40 Build Your Own Electric Vehiclet
- Page 66 and 67:
42 Build Your Own Electric VehicleI
- Page 68 and 69:
44 Build Your Own Electric VehicleF
- Page 70 and 71:
46 Build Your Own Electric VehicleE
- Page 72 and 73:
48 Build Your Own Electric VehicleF
- Page 74 and 75:
50 Build Your Own Electric VehicleJ
- Page 76 and 77:
52 Build Your Own Electric Vehiclee
- Page 78 and 79:
54 Build Your Own Electric VehicleF
- Page 80 and 81:
56 Build Your Own Electric VehicleK
- Page 82 and 83:
58 Build Your Own Electric Vehicle
- Page 84 and 85:
60 Build Your Own Electric VehicleM
- Page 86 and 87:
62 Build Your Own Electric VehicleF
- Page 88 and 89:
64 Build Your Own Electric Vehiclev
- Page 90 and 91:
66 Build Your Own Electric VehicleF
- Page 92 and 93:
68 Build Your Own Electric VehicleF
- Page 94 and 95:
70 Build Your Own Electric VehicleF
- Page 96 and 97:
72 Build Your Own Electric Vehicleo
- Page 98 and 99:
74 Build Your Own Electric VehicleA
- Page 100 and 101:
76 Build Your Own Electric VehicleF
- Page 102 and 103:
78 Build Your Own Electric Vehiclet
- Page 104 and 105:
80 Build Your Own Electric VehicleF
- Page 106 and 107:
82 Build Your Own Electric VehicleF
- Page 108 and 109:
84 Build Your Own Electric VehicleF
- Page 110 and 111:
86 Build Your Own Electric Vehiclep
- Page 112 and 113:
88 Build Your Own Electric VehicleY
- Page 114 and 115:
90 Build Your Own Electric Vehiclec
- Page 116 and 117:
92 Build Your Own Electric VehicleE
- Page 118 and 119:
This page intentionally left blank
- Page 120 and 121:
96 Build Your Own Electric Vehiclei
- Page 122 and 123:
98 Build Your Own Electric Vehicle1
- Page 124 and 125:
100 Build Your Own Electric Vehicle
- Page 126 and 127:
102 Build Your Own Electric Vehicle
- Page 128 and 129:
104 Build Your Own Electric Vehicle
- Page 130 and 131:
106 Build Your Own Electric Vehicle
- Page 132 and 133:
108 Build Your Own Electric Vehicle
- Page 134 and 135:
110 Build Your Own Electric Vehicle
- Page 136 and 137:
112 Build Your Own Electric Vehicle
- Page 138 and 139:
114 Build Your Own Electric Vehicle
- Page 140 and 141:
116 Build Your Own Electric Vehicle
- Page 142 and 143:
118 Build Your Own Electric Vehicle
- Page 144 and 145:
120 Build Your Own Electric Vehicle
- Page 146 and 147:
122 Build Your Own Electric Vehicle
- Page 148 and 149:
124 Build Your Own Electric Vehicle
- Page 150 and 151:
126Vehicle gear 1st 1st 2nd 2nd 3rd
- Page 152 and 153:
128 Build Your Own Electric Vehicle
- Page 154 and 155:
130 Build Your Own Electric Vehicle
- Page 156 and 157:
This page intentionally left blank
- Page 158 and 159:
134 Build Your Own Electric Vehicle
- Page 160 and 161:
136 Build Your Own Electric Vehicle
- Page 162 and 163:
138 Build Your Own Electric Vehicle
- Page 164 and 165:
140 Build Your Own Electric Vehicle
- Page 166 and 167:
142 Build Your Own Electric Vehicle
- Page 168 and 169:
144 Build Your Own Electric Vehicle
- Page 170 and 171:
146 Build Your Own Electric Vehicle
- Page 172 and 173:
148 Build Your Own Electric Vehicle
- Page 174 and 175:
150 Build Your Own Electric Vehicle
- Page 176 and 177:
152 Build Your Own Electric Vehicle
- Page 178 and 179:
154 Build Your Own Electric Vehicle
- Page 180 and 181:
156 Build Your Own Electric Vehicle
- Page 182 and 183:
158 Build Your Own Electric Vehicle
- Page 184 and 185:
160 Build Your Own Electric Vehicle
- Page 186 and 187:
162 Build Your Own Electric Vehicle
- Page 188 and 189:
164 Build Your Own Electric Vehicle
- Page 190 and 191:
166 Build Your Own Electric Vehicle
- Page 192 and 193:
168 Build Your Own Electric Vehicle
- Page 194 and 195:
170 Build Your Own Electric Vehicle
- Page 196 and 197:
172 Build Your Own Electric Vehicle
- Page 198 and 199:
174 Build Your Own Electric Vehicle
- Page 200 and 201:
176 Build Your Own Electric Vehicle
- Page 202 and 203:
178 Build Your Own Electric Vehicle
- Page 204 and 205:
180 Build Your Own Electric Vehicle
- Page 206 and 207:
182 Build Your Own Electric Vehicle
- Page 208 and 209:
184 Build Your Own Electric Vehicle
- Page 210 and 211:
186 Build Your Own Electric Vehicle
- Page 212 and 213:
188 Build Your Own Electric Vehicle
- Page 214 and 215:
190 Build Your Own Electric Vehicle
- Page 216 and 217:
192 Build Your Own Electric Vehicle
- Page 218 and 219:
194 Build Your Own Electric Vehicle
- Page 220 and 221:
196 Build Your Own Electric Vehicle
- Page 222 and 223:
198Trojan Minutes Minutes Weight En
- Page 224 and 225:
200 Build Your Own Electric Vehicle
- Page 226 and 227:
202Nominal Cell Operating Theoretic
- Page 228 and 229:
204 Build Your Own Electric Vehicle
- Page 230 and 231:
206 Build Your Own Electric Vehicle
- Page 232 and 233:
208 Build Your Own Electric Vehicle
- Page 234 and 235:
210 Build Your Own Electric Vehicle
- Page 236 and 237:
212 Build Your Own Electric Vehicle
- Page 238 and 239:
214 Build Your Own Electric Vehicle
- Page 240 and 241:
216 Build Your Own Electric Vehicle
- Page 242 and 243:
218 Build Your Own Electric Vehicle
- Page 244 and 245:
220 Build Your Own Electric Vehicle
- Page 246 and 247:
222 Build Your Own Electric Vehicle
- Page 248 and 249:
224 Build Your Own Electric Vehicle
- Page 250 and 251:
226 Build Your Own Electric Vehicle
- Page 252 and 253:
228 Build Your Own Electric Vehicle
- Page 254 and 255:
230 Build Your Own Electric Vehicle
- Page 256 and 257:
232 Build Your Own Electric Vehicle
- Page 258 and 259:
234 Build Your Own Electric Vehicle
- Page 260 and 261:
236 Build Your Own Electric Vehicle
- Page 262 and 263:
238 Build Your Own Electric Vehicle
- Page 264 and 265:
240 Build Your Own Electric Vehicle
- Page 266 and 267:
242 Build Your Own Electric Vehicle
- Page 268 and 269:
244 Build Your Own Electric Vehicle
- Page 270 and 271:
246 Build Your Own Electric Vehicle
- Page 272 and 273:
248 Build Your Own Electric Vehicle
- Page 274 and 275:
250 Build Your Own Electric Vehicle
- Page 276 and 277:
252 Build Your Own Electric Vehicle
- Page 278 and 279:
254 Build Your Own Electric Vehicle
- Page 280 and 281:
256 Build Your Own Electric Vehicle
- Page 282 and 283:
258 Build Your Own Electric Vehicle
- Page 284 and 285:
260 Build Your Own Electric Vehicle
- Page 286 and 287:
262 Build Your Own Electric Vehicle
- Page 288 and 289:
264 Build Your Own Electric Vehicle
- Page 290 and 291: 266 Build Your Own Electric Vehicle
- Page 292 and 293: 268 Build Your Own Electric Vehicle
- Page 294 and 295: 270 Build Your Own Electric Vehicle
- Page 296 and 297: 272 Build Your Own Electric Vehicle
- Page 298 and 299: 274 Build Your Own Electric Vehicle
- Page 300 and 301: 276 Build Your Own Electric Vehicle
- Page 302 and 303: 278 Build Your Own Electric CarFi g
- Page 304 and 305: 280 Build Your Own Electric CarEast
- Page 306 and 307: 282 Build Your Own Electric CarGeor
- Page 308 and 309: 284 Build Your Own Electric CarOreg
- Page 310 and 311: 286 Build Your Own Electric CarPlug
- Page 312 and 313: 288 Build Your Own Electric CarGove
- Page 314 and 315: 290 Build Your Own Electric CarCush
- Page 316 and 317: 292 Build Your Own Electric CarGras
- Page 318 and 319: 294 Build Your Own Electric Car3E V
- Page 320 and 321: 296 Build Your Own Electric CarEV S
- Page 322 and 323: 298 Build Your Own Electric CarPaul
- Page 324 and 325: 300 Build Your Own Electric CarCurt
- Page 326 and 327: 302 Build Your Own Electric CarAvco
- Page 328 and 329: 304 Build Your Own Electric CarLead
- Page 330 and 331: 306 Build Your Own Electric CarGras
- Page 332 and 333: 308 Build Your Own Electric Car•
- Page 334 and 335: 310 Build Your Own Electric CarAsso
- Page 336 and 337: This page intentionally left blank
- Page 338 and 339: 314 IndexAssociation for Electric a
- Page 342 and 343: 318 Indexcosts (continued)EV conver
- Page 344 and 345: 320 Indexelectrical system (continu
- Page 346 and 347: 322 IndexGGage, Tom, 69Galvani, Lui
- Page 348 and 349: 324 Indexlithium-ion batteries, 9,
- Page 350 and 351: 326 IndexPlymouth Arrow, 84pollutio
- Page 352 and 353: 328 IndexTaylor, Carl, 294Technolog
- Page 354: This page intentionally left blank