EVCO EV Conversion Course Manual/Overview of Conversion Steps

From Manual

Contents 1 Overview of Conversion Steps 1.1 The Vehicle 1.2 Preparing the Vehicle 1.3 Primary Assembly and Initial Installations 1.4 Final Installations, Wiring, and Preliminary Testing 1.5 Final Setups and Configurations, Completions!

Overview of Conversion Steps

Reproduced with permission from Brian Weekly and Richard Lane

With what reading I have done and with help From Richard Lane, the following information has been presented here for a general overview of the procedures to convert a gas powered car to a battery electric powered Vehicle.

Robert Weekley, Webmaster, Electric Vehicle Society of Canada

This procedural outline has been done free of charge and may be distributed as free source information but not to be used in any for profit publication without credit to Richard Lane, REV Consultants Ltd.

"This is a basic list. Many steps here require detailed design and testing before continuing on to the next phase. Use at own risk. No Liability assumed as a result of using this list as a total guide to a 'Do-it-yourself' EV Conversion Project, it is strictly for information purposes, so you may know of the major steps involved."

Idea: to convert a car from Gasoline to Electric

The Vehicle

1. Read & Study
2. Decide on Possible Donor Vehicle, AC or DC Conversion, Voltage Desired
3. Plan Location, Type and Number of Batteries/Cells Most important step!
4. Acquire Donor Vehicle
5. Prep Vehicle – Rust removal? Don’t start with a rusty vehicle!
6. Safety Check Vehicle
7. Any remaining Safety Issues
8. Acquire Electric Vehicle Components: Motor, Controler, Throttle, Battery Boxes, DC-DC Converter, Battery BMS

Preparing the Vehicle

1. Remove Radiator, etc.
2. Engine & Transmission Removal
3. Remove Gas Tank, lines, etc.
4. Clean up Engine Bay, steering and brake parts
5. Prep Vehicle – Suspension
6. Separate Engine/Transmission

Primary Assembly and Initial Installations

1. Mate Motor to Adapter Plate
2. Mate Adapter Plate to Transmission
3. Install Motor/Transmission Assembly
4. Prepare and install power brake pump / power steering mods.
5. Arrange Battery Boxes, design, build, install
6. Design, build, install heating system.
7. Prepare Required Gages (Volts, Amps, E-Meter)

   Individual Cell/Battery monitor is more valuable than E-Meter

8. Prepare & Install Throttle Pot-Box Linkage
9. Install Motor Controller

Final Installations, Wiring, and Preliminary Testing

1. Install Charger & DC/DC Converter
2. Wire Controller, Charger, & Converter
3. Wire Instruments & Gages
4. Install Batteries or Cells in Boxes
5. Recheck suspension at this point
6. Wire Batteries/Cells to Controller, Master Power Cut-off, Circuit Breaker or Fuse
7. Wire up Batteries / Cells
8. Test Circuits & Test Car Readiness

Final Setups and Configurations, Completions!

1. Charge up the batteries
   
2. Ministry of Transport -> Documents – Fuel Change: Gas to Electric
3. If needed – Insure Vehicle
4. Apply for Ontario PST rebate for alternate fuelled vehicles

   (RST bulletin #702)

5. Install Plates -> Custom Plates?
6. Drive Test Car
7. Done! (The Conversion, that is! - Now to determine the Performance - covered later!)

Reference:

Electric Vehicle Society of Canada: Auto Electric Vehicle Conversion - Steps Involved