Electric Amazon

[Volvo Canadian]

Thanks. You would have a reasonable sense of whether it rings-true or not too. I was surprised how inexpensive it is to "fill-up" with electricity, but our rates here are cheap and petrol is not. The #'s are correct.

The argument over where the electricity comes from has been debated and the experts agree it is a much better option so I am okay with just firing a round and calling it good.

[Volvo Canadian]

The electronics to monitor your batteries minutely is a conundrum: The batteries I'm using are extremely reliable and configured so a singe cell failure does not cascade more than 6 cells out of over 7,000. If I keep using these Tesla modules tho, I feel obliged to be able to 'prove' they are functioning as they are supposed-to. It will cost me - $US1500.

[Volvo Canadian]

Hello. Well, I just ordered all of the parts needed for the build. Here it is, pasted from a PDF file. After the item are the number of units, unit price and total price $CAN.

AC 50 Drive System: Motor, 650 Amp Controller, Harness
& Dash Display 50hp peak/continuous 6500rpm
CEV5125 1 4,800.00 4,800.00 G
CEV6073 Heatsink 1 165.00 165.00 G
CEV3195 Main Contactor 1 157.95 157.95 G
CEV5197 AC Universal Encoder End Mount L-Bracket Powder Coated 1 123.00 123.00 G
CEV3146 PFC2500 Battery Charger 1 925.00 925.00 G
CEV3052 96V DC-DC converter (isolated) 1 325.00 325.00 G
CEV3013 Curtis: PB-6 Potbox Style 1 136.62 136.62 G
CEV3042 Class T Fuse 400 AMP 1 56.51 56.51 G
CEV3027 Class T Fuse Block 225-400A 1 60.33 60.33 G
CEV3166 Heinemann Main Disconnect Switch 1 225.00 225.00 G
CEV3029 Cable Emergency Shutoff 10ft with cable end fitting 1 38.57 38.57 G
CEV6011 Inertia Switch 1 56.00 56.00 G
CEV6045 EV Pro Fuel Gauge 1 282.24 282.24 G
CEV3035 EV Pro Prescaler with built-in DC-DC 1 114.24 114.24 G
CEV3030 Battery Cable 2/0 per foot 60 4.79 287.40 G
CEV3103 Lithium Battery Cable Ends, Boots, Heatshrink and Markers 1 54.52 54.52 G
CEV6064 Ammeter 500-200 Regen with logo 1 80.42 80.42 G
CEV6024 Heater Element 36V-108V 1500W 2 125.00 250.00 G
CEV3051 Heater Contactor - 14 volt CO coils 2 42.06 84.12 G
CEV6111 J1772 Active Vehicle Control Board (R) 1 71.25 71.25 G
CEV6086 J1772 20 amp Vehicle Inlet with Door and Wire Harness 1 208.40 208.40

On top of this I still have to make adaptors for mounting the motor and purchase the Battery Management System(BMS) once I have the batteries I can determine one critical parameter so-as to make that selection.

Oh - and batteries (plus duty and shipping). As I mentioned these are Lithium-Cobalt-Aluminum Tesla modules from a wrecked Tesla w only 6000 miles on it (see pics). These were $US5000, so approx. $CAN7500 delivered. I'm not sure if I mentioned or not, but comparing battery cost with a P1800 (just converted), he paid $US9200 for 15% less total power (kWh), and his weigh 470 lbs, compared to 225 for mine. He bought the current "top-quality" Lithium Iron Phosphate cells, which as you can see (weight) are far inferior to the Teslas. I haven't compared total volume yet, but obviously it will be much less.

All of the cells plus BMS + battery heater should fit in the wheel-well/fuel tank space. After removing the engine etc and installing the motor + charger + DC-DC converter + Controller + heater (in-car, not battery) plus various switches and fuses under the hood, I think the weight-balance will be a little heavier towards the back, but not much. Hmmm, I wonder if there would be room for the spare tyre? Perfect!

I am stoked about this, mainly because of the batteries. They can eat-up a major cost, but this system is by-far superior. I have a couple of guys in the US who will be able to supply more.

Pics attached. The first is of a complete Tesla battery pack - 16 modules. My build will use 5 modules or perhaps 6. The second pic is of the modules themselves. Inside each are small(!) cylindrical lithium cells - 18x50mm. Six groups of 74 cells in parallel in each module. The third picture is of a partially disassembled module (very difficult), where you can see the cells themselves: The stuff sticking out is the conduit for heating/cooling the cells.

I am now waiting for everything to arrive. Meanwhile, I am rebuilding the engine in my Series 2a Land Rover, but that is another story.

Jim

[dgbalfour]

This will be a fascinating project, I'm looking forward to hearing about it.

[Volvo Canadian]

Hi, thanks. Perhaps starting this thread last week was a little premature, but after New Years I will have the Rover back together and will start on the Blue Dolphin.

Today I decided to buy a label-maker. I will make labels for both ends of every wire - better safe than sorry. The entire battery assy will put out over 500 amps, so mistakes are not easily remedied.

[amazon69]

Those batteries are beautiful. Amazing that they fit in the fuel tank space.

[Volvo Canadian]

Yeah, a real piece of engineering design there. For example, the several (six?) flat metal pieces with the holes in them are where the 74 cells connect in parallel - each one held in place by epoxy, except by a tiny piece of fuse-wire. Functional integration. I should find you a picture - there - attached.

I haven't received my modules yet, as I have now ordered enough to make 2 cars. I doubt I will get such a good price on them again. Christmas will be a bit late.

As for whether they will fit or not, we will see what fits where. The modules are 28 x 12 x 3" and the petrol tank is about 28 x 34." Remember, this is an estate, so I have the entire wheel-well tho. I would prefer to have the batteries on top, and heater etc.... inside the fuel tank space for safety-sake.

[northNH]

Far f**kin' out...

Someone else's somewhat different Amazon project, tho' not nealy as visionary...

[Volvo Canadian]

Cool - front leaf-springs too, just like my Land Rover.

[Volvo Canadian]

Looking at that picture.... The batteries on top are showing the negative terminal, the ones below have a different face - this is the positive terminal. So, the plate also connects 74 positives to the next 74 negatives.

Forgive my dodgey measurement given above - fuel tank is approx. 24x20, so no cells in there. The wheel-well is about 28x34. I measured that very roughly some weeks ago - 28x36 with a little room to spare would fit three modules very nicely on one level, two more on top.

Getting ahead of myself: back to work on the Rover....

jim