Current Projects

Sonoma:

The S-10 pick-up, one of if not THE most common vehicle specific conversion.

This truck started life as a simple 4cyl medium sized pick-up from a GMC factory.  It has a manual gearbox, manual windows, and it's ideal for a conversion due to many factors: It can support the added weight, there's plenty of room to fit the components, and much support for these trucks.  This lucky truck was selected due to it's low mileage and clean condition.  It's barely been used.

Every time we speak with the owner, he's come up with another cool idea for the truck.  We're assured this is going to be one of the best S-10 conversions running on electrons.  When it's complete, you won't recognize it at all.  Think: flat black and 20's.  It'll be sinister.

The conversion:

With the engine removed, as well as all the supporting equipment, there's a ton of room under these trucks.  We are fitting 96 X 90Ah LiFePO4 cells, for a 288V traction pack, giving a total of nearly 26kWh.  The Pack will be accessible via a hydraulically lifted bed.

The drivetrain is an AC-55 from Azure Dynamics, a local BC company in the EV industry.  It will be paired with Azure's matching water cooled controller.  Specs are impressive, with peak torque at 280 N-m, this huge motor is typically meant for trucks and buses, between 5,000-11,000 lbs. 

This drivetrain should move this Sonoma quite well!

Vanagon:

A VW van makes an ideal EV. Not because it's lightweight; they can carry 8 passengers but they are no featherweight.  They're not aerodynamic in the slightest way.  They're reliability is a matter of opinion, but typically thought of as less than ideal.  In it's defense, it was usually the gas motor causing the problems, not the rest of the vehicle.

So why do VW vans make good EV's?  Because they're cool, and you can make anything an EV, some are just better at it than others. 

But not many vehicles are as good at being vans, as VW vans.  If you had a choice of vans, you wouldn't pick the Aerostar, or the Caravan, you'd go for the VW. The Microbus and Westfalia are icons in both pop-culture history and many peoples fond memories.  

This particular VW van is a Vanagon, circa 1985.  It has been stripped of it's 4cyl gas engine, and will be receiving a host of EV components.  The motor is a Warp 9" from NetGain, which will be powered by 12 X 12V FLA batteries rated at a touch over 100Ah.  Using 12V batteries will help to reduce the additional weight added during the conversion, helping to slightly increase it efficiency.

Range is not a priority for this Van as it only has short distances to cover with plenty of charge time available.  This combination will provide sufficient torque to overcome the steep hills of North Vancouver, BC, where it will reside.

Miata:

The Miata has been chosen for it's many EV-esque qualities.  It's lightweight and simple, so it will be easy to convert.  There are literally millions of them on the road, and they are a well built vehicle.   It's a classic roadster layout, built with the enthusiast in mind.  Mazda maintains the Miata is one of the most commonly raced production vehicles made, and we believe it.  

It has 4 wheel disc brakes, Independent rear suspension, and near perfect 50/50 weight distribution.  

Removing the ICE engine and supporting systems will shed a considerable amount of weight, and free up ample room for the conversion components.  

Various levels of performance are available for the Miata Conversions, starting with a DC motor and Lead batteries, and working up to AC powered by Li Ion.  Lightweight and efficient, or lightning quick, and everything in between.
 

Project Sambar:  AC Li Ion Kei Van

Vehicle:  Subaru Sambar Dias II 4WD
4Passenger, Glass Roof
Curb Weight (stock): 990kg
Intended range: 200Km
Intended performance: Significantly better than stock
Conversion Cost: $30,000-40,000 CAD

Vehicle Description:

We love Kei Vans.  Seriously, they are beyond cool!

They are also an ideal EV: lightweight, functional, tons of options, and all in such a great package.  They're small, maneuverable, and very efficient with their low rotating mass and smooth shape.

These are all beneficial traits for an EV, and the Sambar has more still to offer.

The engine is located between the rear drive wheels, and it has optional FWD.  This layout is ideal for weight distribution and installation of conversion components.

It has Electric Assisted Power Steering from the manufacturer, such a good benefit to have.  It's factory equipment, designed specifically for the vehicle, and it saves a considerable cost.  This power steering requires no attention whatsoever during the conversion as it is powered from the 12V accessory system.

A couple electric heater cores will take care of the dual heaters, front and rear, and the A/C will be manual =>  Open Roof.  The stock cooling system ran the length of the vehicle.  The radiator was located upfront along with dual heater cores for the cabin.  The coolant was then routed back to the engine.  It took forever to heat up, could never get enough heat into the cabin in the winter under anything but full load.  All these lines and fluid to fill them are unnecessary and will be removed, saving a ton of weight and clearing more space.  The electric heater will be an improvement in both readiness and capacity.  

Removing the spare tire, AC system and fuel tank will clear a space directly in the center of the vehicle:  35" Wide by 46" Long between the frame rails, and significantly larger clearances below them.  There's enough room for massive battery pack, keeping the added weight directly in the center of the vehicle, mounted as low as possible.  The handling of this vehicle should be dramatically improved due to the new ideal weight distribution.  

This Sambar will be retaining it's 4WD system, a very uncommon feature for an EV conversion.   Subaru is renowned for their expertise in 4WD, and the Sambar is no exception.  It's scaled down, but still quite robust for such a lightweight vehicle.  We certainly hope so because it's limits will be tested with an electric motor entering the equation.

Though the CVT transmission is ideal for this vehicle in stock form, it will not handle the instant shock from doubled torque the electric drivetrain will provide.  An alternative option for gearing with higher capabilities will take it's place, and the option of running either 2WD/4WD will be added to help increase efficiency when the 4WD is not needed.

The replacement drivetrain is in development and promises to be a significant improvement over the stock 660CC 4 cylinder engine with a supercharger.  The stock engine was rated at 40KW and 69 N-M of Torque ( 55HP, 50 Ft-lbs).  The AC motor planned will produce 115lb-ft of torque, over double the stock amount.

The batteries will be Li Iron Phosphate cells (LiFePO4), the capacity has yet to be determined. 

Efficiency is valued over maximum power output for this conversion, however we anticipate this vehicle will still be very quick, and a drastic improvement over stock.

Highway speeds are also a requirement for this conversion, another unideal characteristic to achieve in combination with long range and 4WD.

We can't wait to get this Sambar running on electrons!