It's officially underway... 1986 Mazda RX7 EV project!

[GasSavers_BigMouse]

I'll eventually install a ceramic heater for heating. I wasn't going to mess with any generators on this car. Haven't had much chance to work on the project in a while, lots of life changes, but the higher gas prices go the more motivated I get ;-)

[GasSavers_BigMouse]

The project is not dead! I've collected over 130 NiCd cells ranging from 36-42Ah each (1.2v). I hadn't had a chance to work on the project in the last couple months, mostly because of a change in jobs. Left the aviation field for something more profitable, but before leaving, I took full advantage of my flight benefits. Traveled during all my free time, using up all my remaining vacation time as well. Finally starting to get a bit settled in my new job now, so I felt some motivation to get back to work. This evening, I spent most of my time cleaning out some clutter in my garage so I actually COULD work on something. Once that was to a point where to garage was usable again, I grabbed my variac, two block diodes, a 3-prong plug, and some appliance wire. With these items, I started putting together what will be my battery charger. I bought a variac that claims to have a voltage output of 0-140vac with a 120v input, but I can't get any more than 120 out of it. Perhaps I'm doing something wrong, not tapping it right or something. I need to get over 120 if i'm going to charge a 120v battery pack.

anyway, after losses through the rectifier, I'm getting 106-107vdc. Definately need to bump that up unless I want to drop my pack votlage to 90 or so. Which I don't want to do.

Next on the list, make bus-bars for the cells from copper pipe, run the cables, order replacement parts for my motor control (fried what I've got, trying again), make cable ends... the list goes on.

[Zerodrift]

On a side note, Corksport now makes a nice lip for the S4 (86-88) Rx-7's. I have one and its definatly a nice product. I havent tested it, but I do notice better stability at freeway speeds.

[GasSavers_BigMouse]

Got my variac wiring figured out and hooked up 78v worth of batteries with aluminum bus bars (probably a bad idea, but copper is so $$$).

Anyway, charging the pack now at 4-5a, water level is coming up on the batts, so that's good. Still trying to decide what to do for a controller, will probably keep messing with making my own until it proves too difficult, then just buy a curtis or something. Next thing to try is the open source one I found on the EV list a while back.

Anyway, just a quick update to keep the thread alive.

[jBubb]

THANK YOU for this thread.

I have decided to go the EV route myself and have A LOT of research and reading to do.

[GasSavers_BigMouse]

Finally gave up on the home-built motor control. I've got through too many IGBT's and electronic bits, and they're not cheap.

[tom_eberhard]

Originally Posted by BigMouse

Finally gave up on the home-built motor control. I've got through too many IGBT's and electronic bits, and they're not cheap.

Any updates on the project? Hang in there!
Tom.

[rgathright]

Hey Tom, I am new to the boards but not new to EV's.

I really want to see those controller breadboard pics but the link is down. If I can see your design, I may be able to help you refine your problems.

Don't give up!