No pistons, no fuel, no worries! Toyota Sera EV Conversion begins…

[VA61DETT]

That would be bloody awesome!

I dunno how the motor / batteries would hack it...
Would need to keep a close eye on brush temps n stuff..

-A

[TERRA Operative]

You gotta stick it on the dyno too. We want ruler flat torque curves.

[TC1600]

I would expect it to look something like this:



Top is power, bottom is torque (electric motors produce max torque at 0rpm).

[VA61DETT]

That's about what I would expect, nice work on the dyno graph !

-A

[MWP]

Originally Posted by TC1600

I would expect it to look something like this:
...
Top is power, bottom is torque (electric motors produce max torque at 0rpm).

It was quite odd to see that Prius on the dyno.
A pure electric car will produce a different dyno sheet though i think.
Remember that the Prius also has the petrol engine and some funky transmission stuff working too.

TC1600, can you do me a favour though and host that photo on imageshack?
I dont think my employer would be too happy about hosting that image for you

[thechuckster]

where the fat cables bolt onto the Zilla controller- you might want to paint them with rubber insulation shit or put some heatshrink over them - mostly to stop the bolts loosening off.

[VA61DETT]

TC1600 / MWP

You guys work for "crystalfontz"
As in the funky LCD hardware / Software ppl??

-A

[TC1600]

Originally Posted by MWP

It was quite odd to see that Prius on the dyno.
A pure electric car will produce a different dyno sheet though i think.
Remember that the Prius also has the petrol engine and some funky transmission stuff working too.

TC1600, can you do me a favour though and host that photo on imageshack?
I dont think my employer would be too happy about hosting that image for you

Done, sorry, I got it off another forum, so wasn't aware it would be a problem. Link is here:http://priuschat.com/forums/gen-ii-p...is-dyno-3.html. Not sure about the power graph, but I would expect the torque curve to be somewhere around the mark.

VA61DETT: Nah, I work at Ultra Tune lol, see reply above.

[MWP]

Originally Posted by TC1600

Done, sorry, I got it off another forum, so wasn't aware it would be a problem. Link is here:http://priuschat.com/forums/gen-ii-p...is-dyno-3.html. Not sure about the power graph, but I would expect the torque curve to be somewhere around the mark.

Heh, funny how things move around the internet.
I took that photo of the dyno screen, gave it to my boss in the USA (he owns a Prius), he must have shared it with someone, and its moved on from there.

Originally Posted by VA61DETT

TC1600 / MWP
You guys work for "crystalfontz"
As in the funky LCD hardware / Software ppl??

I do, yes
Kinda strange you know about the company since we dont really sell in Aus.
You use our displays/software?

[VA61DETT]

Aah cool

I have loads of other electronics projects, many including small character LCD's
I used to use the crystalfontz software on my net server @ home for displaying random cool stuff... yannow just cus'

I have long term plans to build a custom dash for my VA61 which will include a nice 40 X 2 display for odometer / trip computer stuff.
Have spent loads of time eyeing off suitable LCD's / VFD's

-A

[MWP]

Originally Posted by VA61DETT

Aah cool
I have loads of other electronics projects, many including small character LCD's
I used to use the crystalfontz software on my net server @ home for displaying random cool stuff... yannow just cus'

So your using CrystalControl2 then?
Thats my software

I have long term plans to build a custom dash for my VA61 which will include a nice 40 X 2 display for odometer / trip computer stuff.
Have spent loads of time eyeing off suitable LCD's / VFD's

Send me a PM... might be able to send something you way

[Talasas]

Loving the work so far, quality is right up there.

Question, where do you get the terminals for teh massif cable and how do you crimp them? I have some 0 gauge battery cable and it's very hard to find suitable terminals for them - maybe I'm not looking in the right place because I've never even seen 0000 cable before. It's also hard finding isolation posts.

[VA61DETT]

-MWP

Sweet

-Talasas
I bought a hydraulic crimp tool of a Local EV parts distributor (zeva.com.au, now evworks.com.au I believe), it goes up to 70mm^2 cable.
He also supplied some of the large terminals, you can also source them from welding supply places and electrical distributors.
I got my big ones from www.evsource.com
I scored all the monster cable from my local scrap metal yard, they get some massive stuff in from time to time, I have seen more then 4 times that thickness!!, bloody crazy big industrial stuff from underground mining equipment.
Get it for whatever the going copper rate is...

[Scuzzy]

Very cool project! I was given the link to your thread by Terra Operative and I've since passed the link around to a few other Sera owners who think its great too.

[VA61DETT]

Cheerz,

Got the next 4 days off, if all goes well I rekon she'll be ready for a test drive by Monday!!!
Can't wait

-A

[RA35GT]

Sweeeet!!!

I expect to see skids down your street

[wagonist]

I was about to say it'd be funny to pull into one of those old fashioned "full service" service stations where they ask to check the oil, etc under the bonnet, but then I remembered you wouldn't be pulling into one of those unless you wanted a coke or something

[RA35GT]

Originally Posted by wagonist

I was about to say it'd be funny to pull into one of those old fashioned "full service" service stations where they ask to check the oil, etc under the bonnet, but then I remembered you wouldn't be pulling into one of those unless you wanted a coke or something

Hehe.

In the future I can see electric servo's with meter boxes and charging sockets all over the place. (They already have similar things in the US, can't remember exact details it was in some tv show I was watching a while back).

[VA61DETT]

Update
Thursday, 1 October 2009

Finished routing & clamping the fat power pipes down the car, can cross that one off.



Re-built the A/C system, new expansion valve, dryer & all new o-rings.


Sorted out all the non-essential wires from the ECU loom, tagged and turfed!


Installed the 60A DCDC converter and assocated power distribution bits.


Have also put in new g/b seals and re-installed the CV’s.
Few more wires to run & I should be able to get the dash back in!
Was hoping to have it ‘test driveable’ by yesterday, but I decided to wait and get as much of the bits for the dash right, as it is a big job to install / remove.

-A

[Scuzzy]

Originally Posted by VA61DETT

Was hoping to have it ‘test driveable’ by yesterday, but I decided to wait and get as much of the bits for the dash right, as it is a big job to install / remove.

Ha very much so, the fact its one piece the whole way across and down to the floor causes a huge headache when you need to get to anything behind there!