DC-DC Installed and New Brake Parts

Porsche 914 EV Conversion

In was eager to get the new DC-DC converter installed so I left work a bit early and got to work so I could still drive the car to breakfast with my girlfriend tomorrow morning. The DC-DC converter fits rather nicely in the old space.

KIT presenting modular battery concept for electric bus

Green Car Congress

Source: KIT. At the upcoming IAA International Motor Show in Frankfurt, Karlsruhe Institute of Technology (KIT) will present a modular battery concept for the efficient operation of an electric bus; an electric city bus demonstrator will illustrate the concept. Source: KIT.

Trending Sources

New DC-DC here and Tranny Fluid Too

Porsche 914 EV Conversion

I let out a major sigh of relief today when the new Iota DC-DC converter showed up today along with the synthetic transmission fluid that ElectroAuto said they would send me. EVParts.com sells it as a DC-DC converter for many of their electric vehicle conversion kits.

AC or DC Drive for Electric Cars?

Electric Cars are for Girls

Why does one select AC over DC drive for electric cars? I see both kinds of kits offered but I don't understand why one would choose

Renesas introduces small, 100kW-class inverter solution for HEVs and EVs

Green Car Congress

Renesas will provide a solution kit including software that maximizes the HEV/EV motor performance and hardware components such as microcontrollers (MCUs), Insulated Gate Bipolar Transistor (IGBT) and fast recovery diode (FRD), and other power semiconductor devices.

2017 28

"Spirit of DC" PHEV All Around America Update. from EVJerry back in DC with the "Spirit" Hanging out at the Beach!

Spirit of DC - PHEV3A

Maybe even provide feedback to PHEV3A Co-Chairs: Joe Lado JoeLado@yahoo.com or EVJerry Asher EVJerry@usa.net (202) 486-5450 "Spirit of DC" PHEV All Around America Update - 7 November 2008 I. The basis for the "Spirit of DC" staying over in Arizona through the winter results from the gifting of a state-of-the-art Li-ion battery pack and charger from Delaware Power Systems out of Vancouver, British Columbia, Canada. Winter Schedule Planning for "Spirit of DC: A.

Volkswagen unveils I.D. EV concept; 1st MEB-based vehicle, to launch in 2020; up to 373 miles

Green Car Congress

will be the first Volkswagen built off the Modular Electric Drive kit (MEB). MEB—Modularer Elektrifizierungsbaukasten (“Modular Electric Drive kit”)—was conceived to support the development of a family of pure electric vehicles within brands and across the Group.

2016 26

Hyundai begins rollout of Ioniq Hybrid, PHEV and EV; most efficient non-plug vehicle, most efficient EV in US; powertrain discussion

Green Car Congress

The hybrid power control unit integrates two motor control units (traction motor and hybrid starter generator) and DC converter are all in the same package. All Ioniq Electric models are equipped with standard Level-3 DC fast-charging capability that can take up to 100 kW.

2017 26

Hyundai begins rollout of Ioniq Hybrid, PHEV and EV; most efficient non-plug vehicle, most efficient EV in US; powertrain discussion

Green Car Congress

The hybrid power control unit integrates two motor control units (traction motor and hybrid starter generator) and DC converter are all in the same package. All Ioniq Electric models are equipped with standard Level-3 DC fast-charging capability that can take up to 100 kW.

2017 26

Slowly, But Ever Slowly. Moving Towards Launching "Tour de AZ - Spirit of DC Plug-in Hybrid Electric Vehicle All Around Arizona".

Spirit of DC - PHEV3A

Cheers EVADC'rs, PHEV3A'rs, and EVnthusiasts, One & All, The "Spirit of DC" along with EVJerry has unfortunately experienced a series of delays on various fronts. However, slowly but ever so slowly yet, with a bit of steadyfastness, the "Tour de AZ - Spirit of DC Plug-in Hybrid Electric Vehicle All Around Arizona" moves! with a PHEV Kit, solar panels and a 110-volt inverter on-board.

Volkswagen CrossBlue Coupé plug-in makes its European debut; showcasing the MQB

Green Car Congress

The CrossBlue Coupé—based off the Volkswagen Group’s MQB architecture (the Group’s modular assembly kit for vehicles with transverse-mounted engines)—features a transverse-mounted turbocharged direct-injection (TSI) 220 kW (295 hp) 3.0L

"Spirit of DC" - Back on Blue Hwy known as Pacific Coast Hwy 1 with Re-invigorated with B&B Battery Pac. Thanks to PluginSupply's Robb Protheroe

Spirit of DC - PHEV3A

Cheers PHEV3A'rs, EVADC'rs, and EVnthusiasts, One & All - On Friday afternoon, 30 January 2009, the "Spirit of DC" was operationally in excellent order and happy to be back on the road, trucking from Petaluma via the Bodega Road to the US Coast Guard Training Center and onto Pacific Coast Highway 1 (PCH 1) on into San Francisco on Hwy 101.

Further Reporting Out on EVADC EVolunteering at the Teens Zone at the Green Festival in DC, 10-11 October 2009

Spirit of DC - PHEV3A

And further demonstrated the Junior Solar Sprints kit at various occasions through out the weekend. Cheers EVADC'rs, PHEV'rs, and EVnthusastists, One & All - Still catching up per Green Festival (as of Sunday, 1 Nov 09) where EVADC did have a black Prius PHEV with a solar trailer for showing at the Teens Zone. with this EVJerr's original "copied & pasted" item to the EVADC list serv.

Opinions and Rants

Porsche 914 EV Conversion

I lost much sleep last night obsessing about how I could fix the DC-DC converter and, as a result, I was very tired and had an irritable day. For those of you who have read my blog entries in the past, you know I've blown up the internal FETs of the DC-DC over five times and spent countless hours reverse-engineering the circuit with experts at work to see just what could possibly be wrong with the system. Despite the above rants, the basic kit is good.

More Wiring and ACK, It Doesn't Fit!

Porsche 914 EV Conversion

Here's a front view with the DC-DC converter. WARNING: The instructions provide direction for a different DC-DC converter with the "input" and "output" terminals swapped left-to-right from the DC-DC converter that comes with the AC kit.

DC 2

Volkswagen Group shows 3 hydrogen fuel cell concepts at LA Show: Audi A7 Sportback h-tron; Golf Sportwagen HyMotion; Passat HyMotion

Green Car Congress

Put another way, the fuel cell technology is being developed so as to work as components in the MQB (transverse) kit, the development of which is led by the Volkswagen brand, and the MLB (longitudinal) kit being driven by Audi. Audi A7 Sportback h-tron. Click to enlarge.

DC 7

EV Solutions WarP-Drive Installation

DIY Electric Car

Outfitted with (18) Trojan T-875 batteries (144V pack) and a Curtis 1231C controller, the truck served as our rolling test bed as we developed and tested components for our S10 conversion kits. The WarP-Drive 160/1000 is a 160VDC, 1000 Amp continuous rated output DC controller. Intro.

Christmas Time!

Porsche 914 EV Conversion

On minor disappointment is that the cable supplied in the kit is #2 gauge cable. I suppose the AC kit doesn't require as much current as the DC kit, but I'll take all the efficiency I can get at this point. YeeHaw! The crate from Electro Automotive finally showed up.

Reflections on Converting a 914 to an EV

Porsche 914 EV Conversion

Here goes (in no particular order): Things That Went Well During the Conversion The 914 AC kit from Electro Automotive is a good one. I modified the wiring in the original 914 AC kit (as suggested by Paul Jorg) to turn on the regen when the brake lights came on instead of controlling regen by releasing the accelerator pedal. I even received a few posts from Mike Brown at Electro Automotive, the designer of the kit. If I had to do things over, I might seriously use the DC kit.

My 2007 Dream Project

Porsche 914 EV Conversion

Since I live in Portland, Oregon, I went to a meeting with the Oregon Electric Vehicle Association and found out about several companies that provided drop-in electric conversion kits for existing cars. After doing some research, I found Electro Automotive out of Felton, CA and put down the $13,000 for one of their latest AC motor conversion kits for the Porsche 914.

NMG 2

Toyota introduces 2012 Prius Plug-in Hybrid

Green Car Congress

The PCU features a compact inverter design with direct cooling of IGBT transistors, and converts DC to 3-phase AC to drive MG1 and MG2. VDC up to 650 volts DC. The on-board charging system accommodates single pulse DC 110/220 volt input, and is compliant to SAE J1772 standards.

Forcing a Fit and Letting Sparks Fly

Porsche 914 EV Conversion

In the process of attaching cables to the auxiliary battery, I got a click from the key-switch relay on the right and the DC-DC converter turned on (red light). Also, the instructions for the DC kit may not apply to the AC kit.

EV Toolbox

Porsche 914 EV Conversion

Emergency Equipment cable cutters small fire extinguisher (for electrical fires) Repair Tools Haynes manual for electrical diagrams digital multimeter wire crimper and extra pink,blue,yellow quick-connect crimps two battery wrenches wrapped in electrical tape electrical tape extra cable lugs and hammer-based crimp tool medium hammer LED headlamp extra fuses (DC-DC converter anyone?)

Taking a Day off to see the EV Show

Porsche 914 EV Conversion

They run on 48 volts and the company sells them as a kit for about $3500. He built the DC version of the Electro Automotive kit awhile back and challenged me to a drag duel at Nedra next week.

Wiring up the Front Compartment

Porsche 914 EV Conversion

Here is the 9-in-1 wire for the AC kit pulled through the grommet between the passenger compartment and the fuel compartment. Here's the wiring specified in the DC instructions (supposedly the same for AC) on the relay block. I finally got to work on the electric car again today.

Routing Thick Cables

Porsche 914 EV Conversion

I've already added the 3-hole cap-plug provided in the kit. After cutting all the tape that bound the engine compartment cables together, I slid on the three-hole cap-plug from the kit and bonded it in place with silicone sealant.

More Delays

Porsche 914 EV Conversion

Over the past few weeks I've been trying to contact the folks at Electro Automotive to get the status of the EV 914 kit. They finally responded last night and apparently they're completely buried under the demand for EV conversion kits. He got one of the earlier DC motor kits for the 914 from Electro Automotive. Mike and Shari both have colds and the welder that creates the frames for the battery holders is quite backlogged.

Wiring Things Up and Testing

Open Source Civic EV Kit

Much of my time was spent wiring up the controller, charger and integrator box from the Belktronix kit. I wired the DC-DC converter right into the alternator input connection, again leveraging the existing main fuse in the under-hood fuse box. which shows that the DC-DC working.

DC 2

Silicon Mobility introduces OLEA T222 for hybrid and electric powertrain control

Green Car Congress

A starter kit will soon be announced to complete the offer with AUTOSAR 4.2 France-based semiconductor fabless company Silicon Mobility has introduced OLEA T222, its new solution dedicated for hybrid and electric powertrain control.

Talking with Mike at ElectroAuto

Porsche 914 EV Conversion

We chatted about the blown CCPower DC-DC converter and the engine vibrations. Since I fixed the DC-DC converter, we agreed that I would try to find out which conditions would cause it to blow again, if it does. Apparently I'm the only person with an operational AC kit currently, although several other people are hot on the trail to finishing theirs. Mike doesn't have an AC kit 914 back at the ranch.

We are Green for 12V Electrical!

Porsche 914 EV Conversion

In the process, the DC-DC converter turned on (indicated by red LED) and then slowly decayed to the off state. of the DC instructions, it drives the keyswitch relay coil instantaneously with 12 volts, energizing the coil. Whew!

DC 2

Fun with Rivnuts

Porsche 914 EV Conversion

It's expensive($65), but I suspect it's easier to use than the tool shown in the VoltsPorsche DC manual. I still need to add the spring, cotter-pin and 5mm threaded barrel listed in the instructions, so I hope those come later with the remainder of the kit parts.

Neste Oil joins aireg to promote the deployment of biofuels in aviation

Green Car Congress

Among the current 29 members of aireg are oil companies, airlines, airplane and engine manufacturers, research institutions, and universities such as Total, Lufthansa, Boeing, Rolls-Royce, Technical University Munich (TUM), and Karlsruhe Institute of Technology (KIT). Neste Oil has joined the Aviation Initiative for Renewable Energy in Germany (aireg), which advances the development and deployment of renewable liquid fuels in aviation.

Hauling Lead and Confusing Connections

Porsche 914 EV Conversion

A modification of the prior strap is basically what is suggested in the DC kit instructions. It turns out that the only copper interconnect that fit right out of the kit bag was the completely flat bar with two holes. Tonight was an evening of heavy lifting.

XL1 dive and drive: Volkswagen aggressively optimizes for efficiency in its sleek diesel plug-in hybrid

Green Car Congress

The XL1 is not a product of any of Volkswagen’s modular Baukästen (assembly kits such as the MQB, MLB or MSB, earlier post ). The XL1’s 12-volt electrical system is supplied via a DC/DC converter and a small auxiliary battery. XL1s ready to roll. Click to enlarge.

Closing up more loose ends.

Porsche 914 EV Conversion

One of the other 914 kit converters questioned why the accessory battery couldn't stay in the original tray, but I decided to remove it anyway and have the accessory battery up in the front trunk near the DC/DC converter.

Two Week Commuting Report

Porsche 914 EV Conversion

The DC-DC converter is still working fine, so the car is actually quite convenient to drive. With the motor out, I'm going to look into RPM kits for electric cars that use spinning magnets on the flywheel with a magnetic sensor to generate a signal. Since I don't work Fridays, this is the end of my second week commuting to work fifteen miles each way. Two things have definitely made the car more fun to drive.

2000 miles and counting

Porsche 914 EV Conversion

If the 12V battery is dead, you need a small 12V battery (9V would probably work) to activate the DC-DC converter relay to bootstrap the 12V charging process. If I don't get elected co-chair next Thursday, I'm going to start an open-source EV conversion kit sub-group within the OEVA.

Getting the EV Back to the Shop and Fixing Electrical Stuff

Porsche 914 EV Conversion

Since the DC-DC converter was blown and I didn't want to deal with it, I focussed on some other electrical problems I'd been having. in the kit instructions), through a bolt connecting the large red wires, and then back to the ignition switch.

Ordering a Motor Adapter

Open Source Civic EV Kit

After some significant debate at the Civic-EV Google Group on whether to use a clutched or clutch-less system, I'm going to pursue using a clutched system for the initial revision of this kit.