The Grand To Do List

February 2005

Define the Need

	Description	Page
	Define the use of the vehicle. Daily commuter? Round town? hot rod?	Requirements
	Define the terrain of where it will be used. How steep are the hills? What is your expectation of passing power and top speed?
	Define typical driving routes. How far of distance between home an work? The store? The golf course?
	How many passengers?

Selecting a Vehicle

	Description	Page
	Research for potential donor vehicles (Internet, listserv, other EV enthusiasts/businesses)	Selecting a donor vehicle
	Define the basic measurements for the potential vehicles. Including: Curb weight GVWR
	Short list vehicles based on requirements
	Gather detailed specs on the selected car: Curb weight - weigh with a full tank of gas GVWR Ride height, front and rear Length, width, height Wheel base Gear ratios - all gears and final drive	Donor Car Specs

Selecting a Drive System

	Description	Page
	Rough sketch of vehicle engine compartment and proposed areas for batteries	Donor Car Engine Compartment
	Rough sketch of vehicle (top view) and where the following components will go, ensure adequate space: drive motor transmission, differential controller and contactor dc-dc converter battery boxes radiator, water pump or cooling fan vacuum pump and bottle pot box charger	System Layout
	Calculate size of motor and pack based on car's data - drive the route with GPS and use Terrain and Energy spreadsheet	Estimating Power Needs
	Determine if AC or DC system	AC versus DC
	Select drive motor	Selecting a Drive System

Purchase and Test Drive System

	Description	Page
	Purchase the drive and inverter, including: Throttle pot DC-DC system
	Bench test drive and inverter	Testing the Drive System

Conversion Preparation

	Description	Page
	Degrease and wash as much of the vehicle engine and underside as possible
	Spray WD40 on as many nuts and bolts as you can see
	Purchase a shop manual (not just a "Haynes" or "Chilton" manual - but the official shop manual - you will be amazed at the difference)
	Measure ride height both front and back wheels from the ground to the top of the wheel arch
	Weigh the vehicle before removing any parts. The front axle, rear axle and curb weight (full tank of gas)>
	Sketch an accurate "system layout". This will include the placement of: drive motor transmission, differential controller and contactor dc-dc converter battery boxes radiator, water pump or cooling fan vacuum pump and bottle pot box charger	System Layout
	Analyze the "system layout" for: adequate cooling side-to-side weight front-to-back weight noise cables easy access for diagnosis and repair

ICE Removal

	Description	Page
	Make sure all fluids are drained (oil, radiator, air conditioning, gasoline)
	Remove the engine, fuel tank, fuel lines, exhaust, emission control, cooling systems	ICE Components Removal
	label all wires on the wiring harness - both sides of connection, as it will make selling the motor easier as well as connecting your electrical motor
	put all small parts into zip lock bags and label them for future use (even the parts that will be sold or scrapped)
	Remove the interior area(s) where battery boxes will be constructed
	Organize parts into: Parts to be sold or scrapped Parts to be put back into the vehicle Zip lock bags are handy for smaller parts and screws, label each bag and tape to its' belonging part
	Keep all spare parts until you are finished the conversion (don't sell that engine just yet!)
	Measure, as accurately as possible, the position of the motor mounts.
	If anything was removed from the firewall (e.g. clutch) make a cover plate (from the same material as the car)

Determine Axle Weights

	Description	Page
	Weigh all the removed parts from your vehicle. Determine the distance of the removed parts from the axles (from a side view). From this calulate the load removed on each of the axles
	Refer to the "system layout" diagram. Determine the weights of each component, and its distance from the axles (from a side view). From this determine the load on the axle.
	Adjust the "system layout" to ensure the new load on the axles is the same ratio as the load removed=

Isolating the Transmission

	Description	Page
	Separate engine and transmission
	If not intending to use the clutch then remove the clutch, actuator, hydraulics (if any) and pedal and associated components
	Cover any holes in the transmission with plates made from the same material as the transmission

The Adapter Plate

	Description	Page
	Trace outline of transmission	The Adapter Plate
	Draft motor face specifications
	Determine adapter plate thickness for spline/clutch matching
	Design and draft adapter plate
	Have machine shop build adapter plate from designs, transmission and drive

Motor Mounts

	Description	Page
	Determine exact placement of drive/transmission w.r.t. drive axles	Engine Mount and Drive Installation
	Precisely measure engine mount size
	Design and construct engine mount
	Install engine mount, drive and transmission
	Verify drive/transmission placement for: free running drive shafts in all movements of shocks no rubbing of engine components drive/transmission shaft centerline is parallel to drive wheel centerline
	Install Drive and Transmission

Controller

	Description	Page
	Determine placement for controller ensure no conflict with other devices ensure adequate room for drive and batteries ensure easy access for diagnosis and repair if air cooled, ensure adequate ventilation if water cooled, ensure adequate room for coolant hoses update the "system layout" drawing with any changes	System Layout
	Construct mounting brackets for controller	Controller Installation
	Install controller

Cooling System

(for water cooled systems)

	Description	Page
	Determine placement for coolant pump, reservoir and radiator ensure no conflict with other devices ensure adequate room for drive, controller and batteries ensure easy access for diagnosis and repair ensure adequate room for coolant hoses to all coolant components avoid sharp bends in hoses update the "system layout" drawing with any changes reservoir highest point in the system	System Layout Cooling System Design
	Construct mounting brackets for pump, reservoir and radiator	Cooling System Installation
	Install pump, radiator, reservoir and hoses
	Test cooling system: check for leaks purge air from system

The "Gas" Pedal

	Description	Page
	Determine placement for throttle pot: ensure no conflict with other devices ensure adequate room for drive, controller and batteries ensure easy access for diagnosis and repair adequate ventilation ensure throttle cable is not in the way of other boxes, wires or cables update the "system layout" drawing with any changes	System Layout
	Build mounting plate for throttle pot	The Throttle
	Modify throttle cable for correct length
	Install throttle bracket, pot and cable
	Test throttle pot to ensure: Full range of pot (use an ohm meter) Smooth running of cable

Existing Electrical System

	Description	Page
	Make a list of existing components to keep and those to remove	Overview of Interfacing to the Existing Electrical System
	Power up vehicle to determine what systems work and don't work
	Design and test systems to simulate or interface new components	Interfacing to the Existing Electrical System
	Remove unused wiring, retest
	Design and construct EV control unit for supplementary systems	EV Control Unit

Power Steering

	Description	Page
	Determine if power steering is actually needed.	EV Power Steering
	Select design for power steering system (e.g. will it be motor driven? Will it use EHPS?)
	Determine placement for power steering pump: ensure no conflict with other devices ensure adequate room for drive, controller and batteries ensure easy access for diagnosis and repair adequate ventilation update the "system layout" drawing with any changes	System Layout
	Install power steering and hydraulics, which may include: hydraulic hoses accessory drive motor power steering brackets	Power Steering Installation
	Design and construct power steering control circuit, which may include: power relays on-off switches encoders to determine if steering is actuated integrating control circuits (relays, etc. into a main electrical box) Fuses

Power Brakes

	Description	Page
	Determine design of power brake system (e.g. vacuum? electric? none?)	Power Brakes
	Determine placement for vacuum pump: ensure no conflict with other devices ensure adequate room for drive, controller and batteries ensure easy access for diagnosis and repair adequate ventilation update the "system layout" drawing with any changes	System Layout
	Install power brake system, which may include: Vacuum reservoir Isolating vacuum pump Vibration mounts for pump Vacuum lines	Vacuum System Installation
	Design, construct and install power brake control system, which may include: Spike reduction diode Integrating control circuits (relays, etc. into a main electrical box) Fuses

Cabin Heating

	Description	Page
	Determine design of cabin heating (e.g. ceramic heater, fluid heater, etc.)	Selecting a Cabin Heating System
	Determine placement for cabin heater (if applicable): ensure no conflict with other devices ensure adequate room for drive, controller and batteries ensure easy access for diagnosis and repair adequate ventilation update the "system layout" drawing with any changes	System Layout
	Design Construct and Install cabin heating mechanics, which may include: Removing dash and heater core Mounting brackets Vibration mounts Heater core lines	Installing the PTC Cabin Heater
	Design Construct and Install cabin heating control system, which may include: Control relays Integrating heater control to dash controls Integrating control circuits (relays, etc. into a main electrical box) Fuses	High Voltage System

Batteries

	Description	Page
	Estimate battery pack size	Selecting a Battery
	Select battery type and manufacturer
	Install batteries	Battery Box and Battery Installation
	Install battery safety system, which make include: fuses connectors circuit breakers	Battery Fuses High Voltage System
	Determine type and design of battery management system	Battery Management Systems
	Build, install and test battery management system

Battery Charging

	Description	Page
	Select battery charger	Selecting a Battery Charger
	Install and setup the charger	PFC-30 Battery Charger
	Install and setup charger controller

Battery Boxes

	Description	Page
	Select battery box material	Battery Box Design
	Design boxes based on space
	Build cardboard boxes the size and number of the batteries (add an extra inch to the top and 1/4 inch to each side)
	Take into consideration thermal and electrical insulation needs of the boxes
	Build battery boxes	Battery Box Construction
	Install battery boxes
	Install appropriate heating and/or cooling	Battery Heating
	Install appropriate venting

Suspension

	Description	Page
	Determine size of new springs	Suspension
	Order and install new suspension

Misc