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Build Your Own Electric Car

Build Your Own Electric Car

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Published by Sheryl L Maiorano
ever thought of building your own electric car?
ever thought of building your own electric car?

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Published by: Sheryl L Maiorano on May 18, 2013
Copyright:Attribution Non-commercial

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08/06/2013

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http://www.instructables.com/id/Build-your-own-Electric-Car/ 
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Build your own Electric Car!
by
bennelson
on November 12, 2008
Table of Contents
Build your own Electric Car!......................................................................................................1 Intro:  Build your own Electric Car!..............................................................................................2 Step 1:  Get a car...........................................................................................................3 Step 2:  Remove anything gasoline related........................................................................................3 Step 3:  Adapter plate........................................................................................................4 Step 4:  Coupler............................................................................................................5 Step 5:  Motor.............................................................................................................8 Step 6:  Batteries...........................................................................................................9 Step 7:  Controller..........................................................................................................10 Step 8:  Other.............................................................................................................11 Step 9:  Now you make one!...................................................................................................14 Related Instructables........................................................................................................15 Comments................................................................................................................15
 
http://www.instructables.com/id/Build-your-own-Electric-Car/ 
Author:
bennelson
author's websiteOrdinary guy with no special skills, just trying to change the world one backyard invention at a time.
Intro: Build your own Electric Car!
The "Electro-Metro" Project.Can't afford a Nissan Leaf? No Problem!Build a cheap electric car yourself by removing the the car engine, replacing it with a forklift motor, and adding batteries.I have plenty of videos about this project at:http://www.youtube.com/user/BenjaminNelsonand300MPG.orgThe primary "build blog" for this project is at:http://ecomodder.com/forum/showthread.php/ben-nelsons-electro-metro-build-thread-848.htmlbut watch out! That is a good read for when you have WAY too much time on your hands.For a good intro to basic electric car construction, stick with this Instructable.For more in-depth construction information, check out the DVD available at300MPG.org
 
http://www.instructables.com/id/Build-your-own-Electric-Car/ 
The first thing you need to dois get a car. They are not all equal.I was looking for something lightweight, with no power anything.Heavier cars need more energy to push down the road, thus limiting your range on batteries.Thingslike power steering and power brakes run off the engine, which is going to be removed anyways, rendering them useless. Power windows and locks add weightand complexity to the vehicle.I ended up finding a Geo Metro for sale, for $500. The engine ran fine, and the body wasn't too bad, but I couldn't drive it home because the clutch was messed up. Ohwell, this conversion isn't going to use a clutch anyways!Makesure the car doesn't have anything major wrong with it (other than maybe a blown engine!) You want to do a Conversion, not a Restoration!
Step2:Remove anything gasoline related
Remove anything related to the gasoline internal combustion system.That means that you are going to take off:Gas tankExhaust, muffler, catEngineStarterRadiatorCoolant tankFuel lines and filterand anything else you can think of.Removing all the extra bits saves weight and cleans up the car, making it easier to paint, run wiring, and do everything else in the conversion.If youremove parts carefully,you can sell them to help cover the cost of the conversion. I bought the car for $500, but then sold the engine, gas tank, and radiator for$550.Free car to convert!Makesure to not alter any safety gear. In this case, I was careful to make sure the driver and passenger airbags remain intact and functioning.Here Iam removing the gas tank. I had never removed a gas tank before, and couldn't figure a good way to drain it. What a mess!Here'sa video of me literally lifting out the engine with a pulley and clothes line! Hard to answer my phone with my hands full like that!

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