I'll list out the current setup, but it is probably going to change a bit in the near future.? ?
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Four Sections of Chevy Volt Batteries (Still configured at 48 volts, 8kWh)
Alltrax AXE-7245P (Configured to limit current at 300 amps, and configured to shut down at 36v)
Schauer Battery Charger (Configured for Lithium Cobalt, cutoff voltage is 50.4v)
J1172 Kit for Public Charging, purchased from https://www.tucsonev.com/
ES-40D-56 Electric Motor by D&D Motor Systems, 10 HP, 5000RPMs
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Volt Batteries
These can found cheaper if you look around. I've seen full Chevy Volt batteries sell for less than $1000 bucks on ebay.? Some will say a BMS is not required, but personally I feel your limiting their life as when they get older, the cells will start to charge irregularly. Basically what ends up happening is some cells charge quicker, and become overcharged, slowly degrading the life of the battery.? Even a cheap BMS will go a long way with these batteries.
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Controller
I'm using the older Alltrax because I originally bought it for another CitiCar that I own.? Its capable of pushing up to 72 volts and 450 amps. Alltrax has made some changes and their new models appear to be better.
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Battery Charger
Schauer is in my back yard, I like supporting local companies.? ?These folks are awesome!? ?You can pretty much order a custom charger, albeit they are pricy.? I do personally feel their chargers are top notch in quality.? I have model JAC1548H, normally configured for lead acid.? They reconfigured it for Lithium Cobalt, with a cut off voltage of 50.4v.? It doesn't have a lot of the bells and whistles like the newer Lesters, its just a simple reliable charger that works.? The batteries are kind of sensitive, you should never charge a 48 volt pack past 50.4 volts and never discharge them below 36 volts.?
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The Motor
The original motor seemed to get pretty toasty in the semi hilly terrain that I live in.? ?The D&D model mentioned is a direct drop in, except the existing forced cooling on the CitiCar needs reworked a bit.? I have not done this yet, but its also worth mentioning the new motor doesn't get hot.
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Public Charging
The adapter I purchased was for a Zero Electric Motorcycle.? Basically a public charger will deliver 240v when negotiated.? If your charger is capable of running off 240v, then this adapter will work for you.? The Schauer auto senses its input voltage, so it was a good candidate for this adapter.?
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Minor Upgrades
Radial Tires, a great improvement in ride over the trailer tires that came with the car.? Most of lights have been replaced with LED lights, including the headlights.? Retractable seat belts have been installed.? A 48 volt to 12 volt converter runs all the accessories, no need for a 12v accessory battery.??
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Things that still need done.
GPS speedometer, the new D&D motor would need to be modified a bit to keep the stock speedometer, I'd rather just replace it with a GPS speedometer, I've already purchased one. A better battery meter needs installed, I have a cheap voltage indicator that works pretty well, but I've purchased a nicer one that also shows amps.? The reverse contactor is a bit sticky on mine, I have an Allbright that needs installed, they are a bit more robust anyhow. Pretty much all the wiring needs replaced, but I plan on pulling all the body panels off, making molds and recreating them in fiberglass.? I really hate ABS.? At that time, I'll rewire the car.? For now, I've just been having fun.? Probably going to convert the brakes to disk brakes, I have some ideas, but still researching. I have plenty of battery to spare, an electric heater box is going to be installed for heat.
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Some added notes from my mangled thoughts
Is it worth it?? Well, who restores a classic car to be cheap and save money?? Nope, its not worth it but its cool and fun!? ?The car drives much differently than the original configuration.? Everything is smooth and at this point very reliable.? A 72 volt configuration would give the car more top end for sure, maybe I'll reconfigure the batteries someday, but for now, I'm ok with the top speed of ~35mph.? ?I'm also thinking upgrading to a Shunt Motor would of been a better option as well, as you could get regenerative breaking and overall better performance.? ?
