Plug-in Electic Car

Last summer when gasoline hit $4 a gallon, I decided it was time for an alternative.   Electric was the choice for me, but nothing was available that goes highway speeds and is reasonably priced.     Research online showed that a lot of people had already converted a gasoline vehicle to plug-in electric and that they run reliably and inexpensively.  

Further research online helped me to finalize a design, choose the component parts and  a base vehicle.   My choice was a Saturn with a standard transmission.    As luck would have it, I found one with a blown engine in the next town.    I purchased the car and began dis-assembly of the gasonline parts.   Engine, gas tank, exhaust, starter, alternator, radiator, battery and more,  were all removed and recycled.     The engine compartment was then pressure washed to get rid of the oil and gunk.  

Building up the electric car took 8 months working some nights and weekends, about 210 hours in all.    The additions to the car to convert it to total electric are:  DC motor (bolted to the transmission), a motor controller, fifteen 8V 190Ah lead-acid batteries for a total pack voltage of 120V DC, a DC to DC converter to make 12V to run the lights radio etc, battery charger, electric heater core, and a lot of controls, relays, safeties, fuses and breakers.

The resulting car has a range of about 40-45 miles, can go 70+ mph, and charges at home for about 83 cents.    It makes the daily 32 mile commute with ease.   I still drive a gasoline car for longer trips, but the electric car now serves most of my daily driving needs.   It has reduced my gasoline purchasing by about 75%.

This web site shows the details about the electric car conversion.     Here is a brief video tour of the main components of the electric car, and a video of the first test drive.


Electric Car during recharge, notice the yellow cord plugged in where the gas fill used to be.