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

[brett_celicacoupe]

so expect to see some updates soon!

-A

...............

[Scuzzy]

Posting because I was blue balled thinking there was an update

[VA61DETT]

Yeah yer... was just about to do an update...

Just not much in the way of interesting stuff to photograph....

OK.

Stuff thus far...

Finished cleaning and coating all the battery terminals.... boring and tedious.. but done! (not much to look at)
Designed, proto-typed & tested interface board... more interesting... see blurry photos below…

Freshly transferred artwork


Etched & cleaned up


Assembly in progress


Currently re-wiring the HV distribution board in the battery box and integrating some other components to make the external connections much neater / safer.
I reckon it will be almost-going-again by the end of the weekend, then more photos & videos will ensue!
-A

[VA61DETT]

Quick Update

Everything is back together and running again, nothing blew up whoo!!

Has noticeably more grunt, got wheel-spin in 2nd during take off, 3rd torque steers like a F*&N c#n?t.
really need new engine mounts and rear spring upgrade....

Will try to get some more vids up tomorrow

-A

[Scuzzy]

Got a spare grand for a TRD LSD?

http://www.austarletclub.com/forums/...howtopic=14326

[VA61DETT]

Update
Wednesday, 17 February 2010

Been hard at work over the last few days, finishing off the following:

Battery box wiring, documentation & copious amounts of mods.
Installed a standby charger for the small SLA battery to keep it topped up when left on-charger for long periods of time.
Installed a pin sensor for the fuel flap, so when it is open, the relays are re-configured to charge mode & you are un-able to accidently drive off with the plug attached.
Tested and calibrated dash gauges
Installed battery box lid
Attached a bunch of high voltage warning stickers

Took if for a test drive this morning down to the local weigh bridge, details as follows:
Total weight: 1125kg (less a few interior panels and carpets).
Front: 563kg Rear: 536kg Spatial Anomalies: 26kg ;p

Pre conversion weight (Measured at same weigh bridge):
917kg (1/2 tank of fuel, full interior trim)

Went to do a few runs for the 0-60-100 times, but had to let off the accelerator when the battery AMPS shot up to 600 just after take-off (3rd gear), the pack fuse is only rated to 500A
Have now wound back the max battery amps limit on the ZILLA & will hopefully be doing a decent long test drive in the coming days.

Rear glass lift-back on:


Completed battery Box with Perspex cover:


Completed Zillabox with warning stickers


Unleaded fuel only, I don’t think so!


-A

[mideon_696]

so is this engineered? or did i miss something? lol.

top effort mate

[Hiro]

so is this engineered? or did i miss something? lol.

top effort mate

Shouldn't that be electricered?

[VA61DETT]

Nah, Not yet.. in the list of to-do's...

Along with A/C, Heater, Stezza etc...
-A

[Cuzzo]

Stereo? wat would it run on there is no motor?!

[gearb0x]

Stereo? wat would run it on there is no motor?!

since when did stereos run on petrol?

[VA61DETT]

???

It Still has a 12v system, everything works the same as normal!

I Have a small 12V SLA which is used for the immobiliser / central locking etc.
Once you switch the IGN on, there is a 150 to 13.5v/60A DC-DC converter that kicks in & helps run all the usual ACCs.
Works just like yer alternator

-A

[willwal98]

I've been meaning to ask you if there are any plans to add a small diesel generator, Top Gear style?

[VA61DETT]

Update
Tuesday, 9 March 2010

Hi All,

Not much to report in the way of updates lately, I have been busy lately testing & logging several trips to work & back in order to workout the all important maximum range.
I have a few mixed results due to issues with my battery meter not reaching %100 charge, so the numbers have had to be re-calculated to take into account the error.

Here are a few useful bits of info:

Orig Weight (1/2 tank fuel, no people)
917Kg

Modified Specs
Total weight: 1125Kg, (less some interior bits)

meas comp old diff
Front: 563kg 576 551 +25kg
Rear: 536Kg 549 366 +183kg
error: 26kg (compensate +13kg each end)

Weight Distribution
Old car ~60:40
Mod car ~50:50

Range info:


My Test Trip


Still need to perform some 0 to 60 to 100km/h tests.
I rekon it will be close, if not quicker then the old 5E

-A

[wagonist]

Have you had any reactions from others?

Worked out a deal to charge it up at work? Ultra long extension cord, Beverly Hillbillies style (let's see who's old enough for this).

Your run looks like more open road style. Is this correct?
Because your distance to work is similar to mine (but your travel time is half), but I've got a lot of traffic lights to contend with. The stationary bit isn't the problem, but the accelerating away from them.