Project: Single Person Electric Vehicle

[PDenbigh]

<nerd>

For my senior thesis at JMU in 2002, I built this:

(click for larger picture)


Hand built box steel frame, drive train built from Mountain bike parts. 48 Volt system, 5hp electric motor. Hand laid carbon fiber body, recumbent seating position. Standard pedals just like a car, etc. Max speed was around 40mph and it was a lot of fun. Problem is, the steering wasn't up to the task and it'd flex or break if I took a high-G turn.

So, I've decided to build version two. Call it project-itus while the XR is gone. I drive a 4.6 V-8 F-150 at 15-18mpg, every day. For 95% of what I do around town, I don't need it. 23 gallon fill-ups get old too. I have always had "a thing for" the environment and I'd love to have an electric vehicle as my daily driver so that's the goal.

This time, however, I'm using real steering parts, real suspension parts, and the rear end from a sport bike. I'd love to hit 60mph and by my calculations it's not too hard. Range is around 10-20 miles depending on driving style (5 miles for me...). It will probably end up looking more like this device made by my heros at MIT last year:


I'm not claiming to be an engineer so a lot of my project is not "built from scratch." I prefer to take preexisting, proven systems and just use them in a different way.

So, when I'm asking for random things, now you know why!

</nerd>

[Ryan T]

That is so awesome Pete, I can't even begin to describe how awesome that is. I'm sure all of MM will be more than happy to source random ass parts for you, I know I will.

[Apoc]

How does one get something like that licensed for road applications?

[BLINGMW]

Super cool. 8) I wonder... could you get suspension parts and such off of a wrecked/old Formula Ford or something? A retired FSAE kart? Is there a forum where those guys hang out? It would seem that could save you some time with at least the front suspension question.

[PDenbigh]

How does one get something like that licensed for road applications?

Good question, one I made sure I could answer before diving in ;-)

I'm building it as a "Custom built motorcycle" to make the registration process SO much easier. It's not too hard to get your "own, custom built, one-off" machine legal. Now, if I wanted to sell them on the mass market, that's were it gets sticky.

[PDenbigh]

Super cool. 8) I wonder... could you get suspension parts and such off of a wrecked/old Formula Ford or something? A retired FSAE kart? Is there a forum where those guys hang out? It would seem that could save you some time with at least the front suspension question.

Very good idea Chan. I actually spoke with Hunter a few days ago about where their FSAE team gets parts, turns out they're all custom built. But, I should look into used/retired parts....

Thanks!

[white_2kgt]

How does one get something like that licensed for road applications?

A 3-wheeler would get classified as a motorcycle (and require a moto license to operate), he just gets issued a VIN from the DOT and then it has to pass a motorcycle inspection, basically. Same way custom hot-rods get tags.

[Steve85]

Very cool! I would love to build a car from the ground-up...any type of car/vehicle

Good luck on the project and I will keep an out for your oddball requests.

I have an extra transverse fiberglass leaf spring that might help cut some weight and simplify the front suspension...just a thought

[PDenbigh]

Thanks to Rex's suggestion, I just found/ordered these two books:

[CaptainHenreh]

Pete, that's really cool! My dad and I have been kicking around converting one of the Metros to full-electric, but so far it's been all talk.

PLEASE keep us posted on your progress. My guess is that if you built it and wrote a good, informative book it could probably pay for itself.

[D_Eclipse9916]

Pete, sounds awesome! I got some suspension coming in to replace my stock shock/intrax spring combo, if you need something to borrow or use, let me know, I still have the stock springs too, but they may be too stiff, although you may be able to pick up gs-t or gs springs which are softer and use them with the stock GSX shocks which are gas-calibrated KYBs. However, depending on how big that thing is, it still may be way overdampened and overspringed.

Make sure to post up stuff, a lot of us have random parts laying around.

[PDenbigh]

Pete, that's really cool! My dad and I have been kicking around converting one of the Metros to full-electric, but so far it's been all talk.

PLEASE keep us posted on your progress. My guess is that if you built it and wrote a good, informative book it could probably pay for itself.

There are some electric Metros around. Google should help you there. I had origionally set out to build an electric Triumph Spitfire. However, after doing the math of the GVWR I couldn't get enough juice in that baby to make it super useful without spending a pretty good amount of money. ($8k).

This thing that I'm building needs to be light. The simple design and 3 wheels are for that goal.

[PDenbigh]

Pete, sounds awesome! I got some suspension coming in to replace my stock shock/intrax spring combo, if you need something to borrow or use, let me know, I still have the stock springs too, but they may be too stiff, although you may be able to pick up gs-t or gs springs which are softer and use them with the stock GSX shocks which are gas-calibrated KYBs. However, depending on how big that thing is, it still may be way overdampened and overspringed.

Make sure to post up stuff, a lot of us have random parts laying around.

Thanks for the parts offers DJ! I'll keep you posted!

[white_2kgt]

Thanks to Rex's suggestion, I just found/ordered these two books:

I have this book. Really engineered more towards race car's and such and has a few errors (I'd have to look at my notes to remember what they were). Not sure you are going to find it useful for what you are trying to do.

On the coleman catalog. While it has A LOT of stuff in it, if you find something 'close' to what you want, call them up, they have/can get a TON more stuff that just what's in the catalog.

[Hunter]

But, I should look into used/retired parts....

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That's the FSAE forum that a lot of people ask questions on, You could look for old cars and parts from them for sale. I know we just sold one of our old cars to some team looking to get started in fsae in the midwest.

[REED]

I drive a 4.6 V-8 F-150 at 15-18mpg, every day. For 95% of what I do around town, I don't need it. 23 gallon fill-ups get old too.

I hear ya on that - for the amount of driving I do even a Civic seems like a waste. I'm probably a perfect canidate for an electric vehicle.

Good luck with the build - the idea of constructing something of this complexity, be it from scratch or otherwise is just beyond me.

[BLINGMW]

In FL, but would seem perfect!

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[PDenbigh]

That's neat! I think you should buy it and put your M10 in it ;-)


I found an entire Triumph Spitfire front end for $160 shipped to my door, including all control arms, spindles, hubs, wheels, etc. So, that's going to be the "version 2.0" of the front end.

[BLINGMW]

sweet! :thumbup:

[PDenbigh]

Motorcycle guys -

I have my choice between the rear assembly from either a F4 or a GSXR.

Any idea which:
is lighter, stronger, or more has a more compact suspension linkage?
can get the largest rear sprocket?
has the better rear shock or ability for the stiffest spring?

Thanks!
Peter