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Electric Car Conversion

Converting a 1993 Honda Del Sol to electric using the guts of an electric forklift

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This project was created on 01/12/2014 and last updated 5 months ago.

Description
NEW PROJECT WHERE I PUT THE GUTS OF THIS CAR INTO A DUNE BUGGY! http://hackaday.io/project/1226-The-Flux-Buggy

In my first year of my Engineering degree, Ian Hillier and I decided to try our hand at converting a car to electric because, why not?

Turns out -- it's not that hard.

Details

​For a complete chronological journey through the process of converting a car to electric, please check out the build logs below. The following is just a top-level description of the project and its outcomes.


Components
  • 1 × Alltrax 72V 450A Speed Controller
  • 1 × Touchscreen laptop
  • 6 × 12V Sealed Lead Acid Batteries
  • 1 × 1993 Honda Del Sol
  • 1 × 36V-12V DC-DC Converter
  • 1 × 3D printed accelerator pedal
  • 1 × GE Series Wound DC Motor (pump motor from forklift)
  • 2 × 36V DC golf cart battery chargers
  • 1 × Analog ammeter
  • 1 × Serial-to-USB adapter

See all components

Project logs
  • Conclusion

    9 months ago • 3 comments

    We did it. We took a 1993 Honda Del Sol, and a equally old electric forklift and merged them together into something we like to call the Delsolectric Car.

    It might not be pretty. But it worked. We even managed to get it up to 100km/h on the used batteries!

    Unfortunately when we looked into getting it insured, we were met with a lot of red tape. Being poor university students we weren't able to pay for the insurance -- or buy new batteries for it.

    It sat in Ian's backyard for the next 2 years until we decided to take it apart and scrap it. Was it a waste of time? No. It was an amazing learning experience. We fully plan on doing another one after we graduate and start working -- which by my count, should be soon! Ian's recently bought a truck and is tempted to convert it into a hybrid using the big drive motor from the fork lift. 

    Until next time... Let me know if you have any comments, there's also more information on my original project blog at www.delsolectric.wordpress.com

  • Finishing Touches and the Virgin Ride

    9 months ago • 0 comments

    Wait a second -- how are we going to control this thing? While a simple ON/OFF switch sufficed for the electric scooters, we don't think it'll work so well with a car...

    We picked up an Alltrax 450A 72V golf cart off eBay for a few hundred dollars -- It also has serial output so we can monitor everything digitally!

    We hooked up the laptop for some initial testing.

    The speed controller accepts a plain old potentiometer as the speed control input -- so we 3D printed our own accelerator pedal to be attached to the existing gas pedal. It works surprisingly well!

    Throw some batteries in the trunk with the chargers...

    Some more in the passenger seat... Oh wait we took that out.

    Charging it up... and off we go! Check out the first test drive video (linked in the main project page).

  • Autobots Assemble!

    9 months ago • 0 comments

    Now that we have a car and a motor, we need to fill in the gaps. First off is coupling the motor to the original transmission of the car.

    In machine shop class I replicated the spline pattern found in the pump motor -- first on the lathe.

    Then on a mill with a rotary index.

    It fits!

    We made a temporary plywood spacer for the transmission, and from that, an aluminum cover plate. 

    From there it was just a matter of installing everything.

    Almost ready for its virgin test drive! But wait -- it's cold out, and we don't have a heating system!

    Is that a kettle element? Attached to the heating coil? Yes... yes it is...

    We were lucky enough to receive these old 6V batteries from our school Conestoga College -- They aren't the greatest, but good for testing!

    Next up the finishing touches, and the first test drive!

View all 6 project logs

Build instructions
  • 1

    Choose a car, preferably without power steering. Remove all ICE components. 

  • 2

    Purchase a high power electric motor, a speed controller, batteries, heavy duty wire, battery chargers, a DC vacuum pump, a DC-DC converter, and main power relays.

  • 3

    Custom machine a coupling adapter for the motor to the preexisting transmission, weld support brackets. Install motor.

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