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The EVMaine Electric Car Project - Page 4 of 4 |
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(Please wait for the new photos to load) Preliminary Parts List and Suppliers
Something new and handy- An LED lights calculator http://led.linear1.org/1led.wiz These solar panels will be the ‘gas station’ in my back yard
Here’s the second PV array ready to go up
Here’s another view of the second panel on my 2x6 ramp. The array weighs about 130 pounds. The extended and pivoting pole top will allow flexibility in coordinating the same orientation of the two arrays.
Here are both arrays up on their eight foot poles. The wiring is not finished in this photo. Yes, I needed help to get them up there without dropping them. Each of the six panels produces 110 watts for a total of 660 watts. This system could theoretically produce up to about 2.5 kilowatts per sunny day in Maine. Expect less. Heavy glass Mitsubishi panels.
Here is the ‘combiner box’ on a pole, then the wires go into the basement to the charge controller and batteries. Ground wires have been added since this photo was taken. This back yard ‘gas station’ will provide enough power to recharge my electric car batteries, but it will take a couple of sunny days.
This is my initial setup for only 12 volts DC. I will also have to add a switching arrangement and separate plug to output 72 volts DC for charging the electric car batteries. In addition I will hook up my 110 volt AC inverter as soon as I can get to it. Do not copy my system, consult a qualified electrician for your own installation. I take no responsibility for anyone else’s system.
Back to Building the Electric Car
NOT MINE! This is the frame and running gear of Art Haines’ latest prototype of his Sunn electric car. My car’s front end is from Art, so it is the same except mine is now five inches wider, and my car has three wheels.
Several new design considerations have come to mind lately. Some possible configurations: 1. Only one door on the curb side. 2. Six batteries for longer range. The 72 volts will keep current draw to a minimum. 3. Maybe add later: A generator trailer that could be pulled to run the car for longer than charged battery range. 4. Streamlining wouldn’t make much difference because my vehicle will be driven mostly around town at low speeds, which is when there’s not much resistance from the air.
This will become the back end of my car. It is from a 1982 Kawasaki 1,000 cc bike. I will weld it to the car frame and then add the electric motor. I made sure I got a bike that had a hydraulic (disc) brake so it could be used in concert with the two front hydraulic (disc) brakes.
This is my front end. Art Haines of www.sunnev.com made it for me. I have now widened it five inchese for more road stability and a smaller turning radius.
These are the front wheels and tires, which are 26 and a half inches from outside to outside of the tread. They are larger and sturdier than bicycle tires.
Above are the long frame members and the front end.
Here’s the frame with most of its crossmembers welded in, and painted. The battery box frame, which will be under the driver’s seat, will be welded onto the frame next.
Here’s the mockup: frame, floor panel, seat, batteries, etc. You can also see the small red wirefeed welder, which is ideal for a project like this. The seat is from a 1999 Dodge Caravan that I got from the local junkyard.
And here’s the back end showing the motorcycle drive parts More (newer) photos HERE... A new and important thought. A sustainable car body material. I have been thinking about making a fiberglass body for this car, but that is fossil fuel derived, plus fiberglass outgasses toxic gases for years. I’d be better off finding a more sustainable, and less toxic material, or recycle some already existing material. What was that East German Trabant car body made of? Cardboard or something like that? Criteria: The material must be reasonably lightweight, malleable and reasonably inexpensive, at least no more expensive than fiberglass, at the most. How about: Recycled cardboard? Bamboo panels? Hemp panels? Thin aluminum panels? A transparent plastic car body? Fabric over aluminum bows? Scrap wood or laminated wood strips? Bubble wrap? Recycled plastic material of some sort? Heavy plastic flexible sheeting material stiffened with something Recycled something else? A new material that is on the market that I am not aware of?
New photos of construction of the EVMaine.org electric car Posted July 12th, 2008
The front body frame is mostly done, and the windshield frame is finally in place.
That is a solar panel for the car roof. It may, or may not be left on there permanently.
The curb side door goes on next, there will be no driver’s side door.
The work is progressing quickly now.
Here the curb sidewall and curbside (only) door frame has been added. The running gear, electrics, electronics and side panels will go on last. The side panels will be made from 4 by 8 sheets of textured fiberglass, which is slightly flexible. A solar panel may go on for the roof later. To First Page of Electric Car Project
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