Woody's Electric 240SX · 16 December 05
We’ll title this,
“Woody’s EV undergoes open heart surgery. Diagnosis looks promising…”
Woody Becher is converting a 1995 Nissan 240SX. I got an email from him a couple months ago when he was trying to use our battery layout tool and wondered how to rotate the batteries. Come to think of it I still haven’t fixed that problem.
For the short term simply lay your monitor on its side…
I’m not sure how long Woody’s been working on the EV or which one of the fellows in the photo is him. Here’s the plan for his electric car conversion:
- Advanced DC Motor 203-06-4004 (excess Corbin Sparrow motor from EV America
- 15 Trojan T-875 8vdc batteries (120v pack)
- Curtis 1221C-7401 Controller
For the rest of the story let’s turn the typewriter over to Woody…
This shows my electric heater core installed in the heater box.
The old heater core is beside it for reference. I installed it in the car and plugged it into 120VAC to test, and it puts out heat and didn’t melt the box or start on fire so I think it will be OK. Just a little scary having that kind of heat that close to the plastic heater box. You can see it installed in dash picture (at bottom of page), it is the only thing in the car besides the steering wheel and passenger side air-bag.
This shows the beginnings to a front battery frame. The cardboard batteries were a great idea. Thanks!
I downloaded the electrical drawings from AHDOL.com. They have any car’s electrical diagrams for 12 dollars or specific sheets for about half that. I paid the 12 dollars and got a PDF of the entire electrical system (40 pages.) It’s come in handy several times already.
Here’s the motor attached to the adapter plate (before I cut the final shape.) Notice the new alignment tool to the left of the motor. The I.D. is the same as the diameter of the transmission input pilot shaft instead of the motor coupling. This directly aligned the center of the hole in the adapter plate with the transmission shaft, eliminating any slop in the clutch plate/coupling assembly. Then instead of just drilling the bolt hole pattern, we drilled two small holes through the plate into the bell housing. Then we inserted spring pins to firm up the alignment. That way when you remove the plate the alignment pins will bring you exactly back to within a few thousandths.
The clearance holes for the bolt hole pattern typically are at least 1/64” oversized to allow the bolts to easily slide through. This movement will translate to the plate when you bolt it in place. I am a chemical engineer and have worked around rotating equipment for some time. We typically would align a 4000RPM motor to much tighter tolerance. Otherwise we tend to see excessive vibration (which you can’t always detect without vibration equipment) that will shorten the life of your motor output bearings and your input seal on the transmission. Of course we run things 24/7, so we see a lot more run hours in a shorter time. You may go thousands of mile with no issue. The spring pins are cheap and the installation only takes a few minutes. Next update I’ll send you pictures of the pins if you would like. [Sure! -JH]
I tried using a saws-all on this plate and experienced your Wile E Coyote earthquake pill syndrome, so I stopped. I was able to use a plasma cutter at work on the adapter plate. This worked very well (<5min.) and produced an OK edge (had to grind a little to smooth out the burrs.) I’d recommend it if you can get your hands on one.
Thanks Woody. A plasma cutter? That sounds like a great xmas stocking stuffer. ”:^)
Here’s a view of his 240SX dash. I’d like to go on record as saying that I hadn’t even considered using a beer bottle while working on the dash, although I can certainly see how it might help!
The scary thing is that it I’m getting a sense of Déjà Vu looking at all of the exposed wiring. And look at the size of that steel pipe running across the front.
Thanks for the pictures and EV update, Woody. Always great to see another conversion and hear how other folks undertake their own project.
If you have an EV project that you’d like to share, feel free to contact me.