Yugo Greg! · 26 August 05
Greg Coleman has been working on an electric conversion project. He was kind enough to let me share details and pictures of the $800 Yugo EV.
The electric is on the left. Note how much higher it sets…
Update from June ‘05:
I have driven the car home tonight for the first time. Road speed is about 35 mph because of the 5 HP motor. This will do as I drive a backroad with light traffic.
I built the car so inexpensively that the complete conversion cost for materials is under $800.00. It cost me almost $350.00 just to legalize the car…title, license and a windshield. I bought everything off eBay and got all new motor, controller (alltrex) and potentiometer, for 1/3 of what others wanted. For batteries I went with 4 deep cycle from Farm & Fleet on sale for $46.99 each.
I have my own machine shop so I made the adapter for $30. Then used a double roller chain with twin sprockets to connect the Baldor motor to the 5 speed trans and no clutch. The car weighed 1800 lbs before the conversion. Now it weighs 1640 lbs.
Range is around 13 miles which works out OK for now. I am looking for a 10 HP motor and putting a bat pack in back seat of Optima (no fumes) batteries when they go on sale again.
I tried to find a bargain charger but they are way too costly, so I built my own. I took a small Sears arc welder that puts out 48 volts when fitted with a full wave bridge rectifier. It wouldn’t bring the pack up quick enough so I added a 12 volt transformer and another full wave bridge rectifier on the side of the original case. Now I get almost 60 volts and charges at 10 amps. Total cost of parts $25.00. I bought the welder and the charger (for the 12volt transformer) at garage sales.
I tried a 100 amp fuse on the pack but blew it on a hill. Now I have a 250 amp slow blow and seems to be fine.
Latest Update 8/26/05:
I did have to add 2 bridge rectifiers in series for EACH transformer but now it charges well.
I now have over 1020 miles on it and just have to add water every 200 miles.
Thanks Greg! Hopefully we can post more pics once he scores a set of Optimas.
If you have a conversion in progress or on the road that you’d like to share with us, drop me a note.