Starting my first EV conversion project 1997 S-10

First some background:

Experience: Changed oil and filters, rotated tires, changed spark plugs, caps, rotors, and wires; swapped / changed stereos, replaced lights and light kits in many vehicles

Tools: socket set, wrenches, hammers, drill, 4 ton jack, two 3 ton jack stands, breaker bars

Motivation: talked about a conversion project in 2005; did not move forward due to my confidence not being there to TOTALLY accept the challenge

Intended use:
Range 40 - 60 miles
Speed average 35 mph, highway up to 60 mph.
Some highway driving
Area - Olympia, WA - Tacoma, WA approximately 32 miles one way some hills and windy roads.
Primary function - commuter
Seating 2 adults
Clutch design preferred

Required:
Small pickup w/ manual transmission, 4 cylinder, 144v battery system, 9" motor and mount, heater, power brakes, and battery heater (maybe due to our climate???)

Decision:
Purchased a functional 1997 Chevy S-10 P/U, White w/grey interior and black vinyl floor; drove it from Everett to Olympia without any problems or warning lights

Included:
2.2L 4 cylinder
5 speed manual
regular cab
power breaks
power steering - replacing with manual steering box and pitman arm ordered and received from Ebay Motors for $106.00 (total)
heater
third party stereo

Not Included:
A/C - not needed
Power windows - not needed
Power seats - not needed
Antenna - needed

Things to be fixed:
Windshield requires replacement
The cylindrical lock on the drivers side is missing, the passenger side is present and works correctly.
Low Rolling Resistant Tires needed.
Three areas of paint chip and possible rust forming requires attention
Vinyl Bench Seat requires replacement
Slight smell from smokers (Febreeze helps, but any advice would be appreciated)

What I done thus far:
Pressure washed engine compartment - twice!
Drained and properly disposed of fluids - engine oil, gas ( filled our generator, pressure washer, and gas cans), coolant, power steering - removed oil filer and plug

Carefully Removed:
Cargo bed - unplugged wiring harness, removed 8 bolts, removed rear bumper sides and off it went.
Exhaust system - manifold, catalytic converter, muffler
Fuel System - intake manifold, fuel lines, gas tank, sensors
Radiator, hoses, and mount
Power steering hoses
Alternator, Fan, Belt, and pulleys
Distributer, spark plug wires, spark plugs, EGR valve
Engine head
Two brackets connecting the engine to the transmission

Note: I CAREFULLY disconnected all electrical connections from engine, exhaust and fuel systems.

What is left:

Take a few measurements - not sure where to begin
Replace power steering gear box and pitman arm with manual steering box and pitman arm
Replace drivers door lock - suggestions welcome
Replace Windshield - suggestions for companies welcome
Replace bench seat - suggestions welcome
Remove engine block - my neighbor has an engine hoist
Figuring how to suspend the transmission in order to push the vehicle in and out of the garage.

Order parts / kit -

I would like the battery boxes to sit under the truck bed -- btw, Electric Vehicles of America sell a Tilt Bed Package I am interested in - suggestions welcome.
CEV sell adapters or $825.00 - Clutch design - any suggestion on a cheaper in price, cut not in quality manufacturer - I do NOT have the skills or tools to construct my own
I would like to build my battery boxes as I can get angle iron from a metal supply in our area for 1/3 I would pay for the battery boxes sold by CEV - if not, I will gladly purchase battery boxes for safety reasons.

I will include pictures when the weather clears.

Question:
Reading many articles, books (Electric Vehicle Conversions by Gerald Wagner and Build your own electric vehicle by Bob Grant), there are a few things I am confused about...

1. There are three relay boxes/switches mentioned in several articles located upper left against the fire wall used for the A/C system. I have those relays and did not have an A/C system - Do I disconnect them?

2. If I am purchasing a motor mount and motor set specifically for an S-10 chassis, do I really need to take measurements?

3. Do to my haste, I forgot to label the wires. I know where the positive and negative ground and terminals went from the battery, but is there anything else I should label?

4. Should I add an additional leafspring to support the 16 - 20 batteries the will be located in the rear? http://www.canev.com/Customer%20Conversions.html -- Though, I must admit, I like the battery box configuration in the front, where you can attach the controller to the left hand side.

4. I left the engine computer connected, What will it be used for? I looks similar to the one shown for the ES-10, upper left, motor compartment, silver box type near firewall --http://www.canev.com/Customer%20Conversions.html

5. Which Trojan Batteries should I get, the T-105 or T-145?

6. 18 - 8 volt batteries or 24 - 6 volt batteries?

7. Should I ask for a mentor via this forum?

Sorry for the length of this post!!!!

	Author	Topic: Starting my first EV conversion project 1997 S-10 (Read 2238 times)
0 Members and 1 Guest are viewing this topic.