OwnerBrian Pawlak
LocationMesa, Arizona US map
Vehicle1992 Ford Escort
Originally donated to UCI in Irvine California, and converted to a hybrid as an engineering project. See WebPage
MotorAdvanced DC FB 4001 Series Wound DC
ADC 9" motor with the shaft on both ends. I have my speed sensor mounted on the back shaft to drive the Tachometer.
DrivetrainOriginal 5 speed manual with the clutch.
ControllerCafe Electric Z1K-LV
1000 Amp Zilla Controller. Hairball interface has trouble codes and 2nd "Valet mode" settings for Amps, Volts etc. I am using the "Valet mode" as a second set of parameters to get better range when needed.
Batteries15 Trojan T-875, 8.00 Volt, Lead-Acid, Flooded
I have automotive style posts.
System Voltage120 Volts
ChargerZivan NG3
120V AC input - can draw up to 24 amps. I use either a 30ft 10AWG or 12ft 12AWG cord to charge. Needs about 10-12 hours to charge from 80% discharge.
HeaterElectric ceramic element in place of the original heater core, just in case I need to defrost the windshield. (I'm near Phoenix AZ).
DC/DC ConverterZivan NG1
120VDC to 12VDC
InstrumentationVoltmeter, Ammeter, Speedometer, Tachometer, Curtis State of Charge Meter, Battery charger indicator light. The up shift arrow indicator light is used to indicate the car is "on".
Top Speed75 MPH (120 KPH)
I have had it on the freeway in 4th gear at 75 MPH. Range decreases dramatically at freeway speeds.
Acceleration0-45 in 36 seconds, at 200 AMPS MAX measured at the motor.
It can do burnouts in first gear when not in "Valet/Economy Mode".
Range50 Miles (80 Kilometers)
50 miles is with the driver only, (150 lbs), at or below 45 MPH and below 200 amps while cruising and accelerating. I also am using the "valet mode" to assure less than 350 amp draw by the motor. 30-40 miles is usual with more passengers and more agressive driving.
EV Miles
Start:662 Miles (1,065 Kilometers)
Current:4,795 Miles (7,715 Kilometers)
Total:4,133 Miles (6,649 Kilometers)
 
    As of 8/2/2008
Seating Capacity5 adults
Curb Weight4,400 Pounds (1,999 Kilograms)
This is an estimate, I have not weighed it yet
TiresP185 60/R14 Continental- Kept at max 44 PSI
Conversion TimeElapsed time was about 1.5 years. I worked on it some days after work for a few hrs and on most weekends. About 4 months with no progress either waiting for parts or waiting for the desire to lay on a concrete floor to work on a car. I also had to do some re-construction of the interior, and most of the wiring harness in the engine compartment needed to be replaced or repaired.
Conversion CostEst between 12-15K.
Additional FeaturesIt has a full front to back "belly pan". Originally I did this to improve aerodynamics, but it also keeps the engine compartment clean, and protects the battery charger that is mounted below the rear seat. The radio antenna and roof rack were removed and the roof smoothed for aerodynamics.
I have been driving to and from work daily since 6-24-08, 5 days per week. It is 47.7 miles round trip. I estimate this is about 70% DOD and it takes about 10 hours to charge.

code by jerry