Part 6 - How far can I go on a charge ?

Previous: Part 5 - Where can I buy the parts ?
Next: Part 7 - How fast will it go ?

This depends on many factors including terrain, speed, temperature, driving style, and of course the design of the car. Most conversions average around 50 miles, with some less and some much more.

A pack can be designed for your needs, generally a car set up for Lead Acid may only get 20-50miles another set up with Lithium batteries can go 200 miles or more.

Several type of EV conversions are discussed here:

Scenario 1: 40 miles on AC or DC

  1a. Using AC motor:

    Controller and Motor: ACP
    Batteries: 28 Sealed Optima 55 Ah
    System Voltage: 336 Volts
    Battery Capacity :
        - Efficiency : 250 wh/mile (average for EVs)
        - Energy required : 250x40miles = 10kWh
        - Ah rating : 10kWh/336V = 29.76 Ah
        - Battery rating needed : 29.76 X 1.8 = 53.57 Ah


  1b. Using DC motor:

    Controller and Motor: Zilla and ADC Motor
    Batteries: 18 Trojan T-875 flooded 180ah
    System Voltage: 144 Volts
    Battery Capacity :
        - Efficiency : 250 wh/mile (average for EVs)
        - Energy required : 250x40miles = 10kWh
        - Ah rating : 10kWh/144V = 69.44 Ah
        - Battery rating needed : 69.44 X 1.8 = 125 Ah



Scenario 2: 137 miles on Elite Power Solutions DC

    Controller and Motor: 9” Advanced DC & Curtis Controller
    Batteries: 44 200ah Lithium Iron Phosphate
    System Voltage: 144 Volts
    Battery Capacity :
        - Efficiency : 250 wh/mile (average for EVs)
        - Energy required : 250x137miles = 34.25 kWh
        - Ah rating : 34.25kWh/144V = 237.84 Ah
        - Battery rating needed : 237.84 X 1.05 = 249.7 Ah

    

    

Some tips for high mileage per charge provided by Gene Cosmano and Jim Stack (Phoenix EAA Chairman)

• For the best efficiency start with a light weight vehicle.
• If possible install close ratio gears in your transmission or lower your wheel size 1 to 2 inches
• Aluminum wheels keep un-sprung weight lower and will add 2 to 5 % more mileage.
• Keep tires inflated to about 8 pounds over factory specks.
• No wide tires
• Look for low rolling resistance tires. This can give you 2 to 3% extra mileage.
• 1-a Weight- this is key. check the eBox and Tesla both done because of light weight. It's the key to any conversion. aero dynamic and LRR is 3-5% but weight is really key.
• 1-bThis is why lithium batteries are so good, very light, very powerful and long lasting on top of reducing weight.
• 2- Regen- this is worth 80% recovered energy in the ACPropulsion system. On any stop or downhill it helps. Coming from Flagstaff could refuel an EV !
• 3- The way you drive is also big. Slower speeds and no racing starts saves a lot. slowing gradually with regen is very good and can avoid a complete stop. You can probably go twice as far at 40 mpg as you could at 60. 1/3 slower 50% farther.
• Any old car develops inefficiencies over time.
• Get a 4-wheel alignment, have it set as close to 0 toe in as possible. Fix any problems if they exist.
• Replace rubber brake hoses and rebuild brake calipers to help retract pads.
• Check wheel bearings for smoothness and replace as necessary.
• Close up front of car and add a belly pan.
• Use a low friction oil in transmission and differentials.
• In general you should be able to push the car by hand.

Previous: Part 5 - Where can I buy the parts ?
Next: Part 7 - How fast will it go ?

Material provided by Phoenix EAA members Ricky Suiter and Abel Saucedo.