EnviroKarma.org - Electric Vehicle (EV) Conversion '...it's (NOT) hard to be Green' - what Kermit should have said

 

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EV kit and components

    $ 4956.30 - EV kit from KTA , incl optional heater and vac pump, tax and S&H
    
    $ 1600.   - 12x 8vgchcx direct from US. Battery, delivered, incl S&H
    
    $  295.   - heavy duty rear springs - CanEV.com
    $  700.   - transmission adaptor plate and hub - CanEV.com
    $   45.   - inst manual and suggested wiring diagrams - CanEV.com
    $   57.90 - S&H from CanEV.com
    ===========
    $ 7654.20 - subtotal for 'electrical stuff'
      -137.50 - refund for unused motor clamp
    $   17.50 - Deltec 50-50 shunt
    $   55.00 - First Inertia switch
    $    5.00 - radio shack mini dpdt toggle switch for instr
    ---------
      7594.20
    
    
    
    

Battery Racks and plastics

    $   50.   - steel 'scraps': various 1x1x.125 angle, 2x2x.125 angle, 4x.25 flat
    $    5.   - 1/4 square tube for hold-down
    $   12.   - allthread and nuts, bolts
    $   12 .  - 1-1/4" x 8' PVC, elbow, connector for underneath
    $   50    - .118 x 4' x 4' clear polycarb for various
    $   47    - 5# Polypro welding rod, only used about $3 worth....
    $   98    - .25 x 4' x 8' polypro for battery boxes
    $   28.	  - .062 x 4' x 8' black ABS for undercarriage shields, etc
    ===========
    $   .   - subtotal 
    
    
    

Donor Car and discretionary items

    $  500.	  - 1997 Suzuki Swift, still running w/ 131k miles and getting 40mpg!
    -  150    - sold engine and radiator on craigslist.org
    $  169    - windshield
    $  500    - wheels/tires: aluminum 13x5.5" wheels, kumho solius kr21 155/80r13
    $         - front struts ?
    ===========
    $ 1019.   - subtotal 
    
    
    
    
    
    

Misc supplies - not in kit

    $   30.   - locktite for adaptor assembly and where needed, enough for a lifetime...
    $    9.   - bolts, nuts, washers for fabricated motor mount brackets, 
                see specific pages for details
    $   17.   - used 1/8" AL plate from scrapyard... should be enough to mount controller, charger, and dc-dc.
    $    3	  - (used 3' of 50') weatherstripping for hood scoop- jcwhitney.com
    $   40	  - triple gauge pod for volt, ammeter, charge - jcwhitney.com
    $   10	  - choke cable for cicuit breaker - jcwhitney.com
    $   20    - misc cable connectors from radio shack
    
    
    
    

Misc tools - 'wanna have'

    $  250      - big battery lug crimper (or rent one). I bought Greenlee k09-2gl crimper www.kvmtools.us
    $    0      - sawzall, sabre saw
    $  172      - engine crane from JCWhitney.com, incl S&H... renting would have been $200/week
    $    0      - welder, grinder or friend who can weld
    $  300.     - used Leister 'Triac S' plastic welder w/ tips
    $    0      - 4" angle grinder
    $    0      - miter saw w/ cutoff blade
    
    

 

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Disclaimer of Liability and Assumption of Risk: Working with high voltages in electric vehicles can be dangerous. Working with welding equipment or plasma torch or sawzall and other power tools necessary to fabricate battery racks or create holes necessary to lay the battery racks within an electric vehicle can be dangerous. The purchaser/builder solely assumes all risk. Further, the viewer of this site, and builder of the vehicle, agree to hold harmless Daniel T. Baker and any associates from all loss, liability, or damage resulting from any failures or defects in any project completed with these instructions. It is suggested that the builder follow common-sense safety procedures, such as the utilization of gloves where working with high voltages, and ear protection and goggles when working with power tools.