Battery

[madderscience]

Hi Chris-

Most of us who are using flooded lead seem to be going for either Trojan or Interstate batteries.   I've heard most people say trojans are the best but I'm sure you can find all opinions.  So far, I have no complaints about mine.   I would suggest staying away from discount and store brands and remember that adage about getting what you pay for.

You could also consider Trojan T-105s which are about 10lbs lighter per battery than the T-145s (also 1" shorter, but same footprint) and 220AH instead of 245AH.  and I bought mine (9 months ago now) for about $120 each from allied battery in seattle.  If a battery shop knows you are making a large order you may be able to fanagle a small discount.

For a car that size, (assuming you want freeway capability and you are planning a DC conversion) don't build it with less than 20 of these batteries, and ideally shoot for 24.   That is a lot of weight, but volvos are sturdy cars and with appropriate tweaks should be able to handle it.   I've got 21 T-105s in my 1985 toyota MR2, which is a much smaller car  (original GVW 2800lbs, though as it sits now it weighs 3400).

Keep in mind lightweight,  aerodynamic and small is better performance-wise (range, acceleration,  etc) for an EV, so unless you need a midsize wagon, you could build a smaller, more efficient vehicle and either get more range, or be able to use fewer, smaller and less expensive components to get the same performance as the converted volvo would have.

Off the cuff, with 24 T-105s in the volvo wagon I'd guess a practical driving range (50/50 at 55mph and on surface streets) of 30 to 40 miles. 

Good luck.