Escort Station Wagon EV conversion
(Click images for full size view)

'92 Ford Escort sta-wgn, 5-speed, white body, heather interior, 108V US-125s, Curtis 1221B, GE motor w/ blower, built-in 120VAC K&W BC20 charger, Goodyear GLS Invicta tires, tinted windows, power mirrors, fold down rear seats, range: 45 miles @ 55mph / 35 miles city (worst case driving), Top speed 65mph, and has SB50 connector in the rear hatch area for optional fast charger.

When taking your EV to a gas repair shop, either allow you to drive the EV into the stall or a quick overview of how to make it move can be given (clutch in, foot on the brake, turn the key, it doesn't need
starting, it is already on, release the clutch and give it some accelerator. I usually get "Hey that's easy enough!" hmm, nothing different).

If there were either a repair/add-on/upgrade performed to your EV, then our local qualified EV mechanic is Mike's Auto Care http://geocities.com/evdriver

EV Tricks and Tips
With both my Blazer and Escort now using Goodyear GLS Invictas, 20% above the nominal will increase your range, by reduce rolling loss.

Shifting
Some people are let the clutch slip as like they were driving a gas car (to keep the engine from dying). There is not engine to stall. I find giving less acceleration, letting the clutch out quicker, and
then applying power with the accelerator is a smooth power transfer that extends the life of the clutch.

Insurance
I have CSAA, and they are others that insure EVs as well.  There are many on the EV List that can discuss what their EV insurance company is, what they cover, and what region they reside in.

I also have the $15/yr tow plus plan. This means that if you needed a tow this plan would cover a 100 mi distance for free (but only a couple of times per year). There are other insurance companies that
offer this, and one can have this tow plan membership without using CSAA insurance (i.e.: XYZ insurance and CSAA membership tow plan) Also see:
  EV Insurance
  ELECTRIC VEHICLE INSURANCE

A 108V system with flooded batteries needs to charge to at least 135V. Each 6V battery is charged to 7.5V x 18 = 135V.  This is an easily understandable mistake since 18 x 6 = 108.  After charge the batteries should settle down at rest to about 119V.  After driving, when the batteries are at 108V (when NOT under load) you are more than half discharged.

If you have a newer battery charger, their chip inside will equalize your batteries. Else, every 10 cycles is a good rule of thumb to equalize your batteries. All this is explained in the Kitty Roden Trojan Battery Report   http://members.aol.com/brucedp/evbatt.txt

The battery posts are the round SAE automotive posts (solid stud). No squishy stud with the bolt hole through the middle.

There two DC-DC converters under the body that provide the 12V power for the lights, radio, wipers
and more. This means there is no aux 12V battery to maintain.

Maintenance
I find whether it is my power hungry, water slurping Blazer or outlet nursing, water sipping Escort, checking and watering the EV once at the end of the month is fine.

A trick that was given to me by a cool Electrician at one of my work sites, is to make the watering easy. With his advise, I when to Home Depot, bought a cheap plastic garden sprayer ($10), unscrewed the the
spray tip (now it squirts), and dedicate it to only be for watering batteries.

Distilled water is what I use, and recommend. Too many experiences and reports are given to me of people that go cheap, using so called 'good for batteries' water (either out of machines or the store. Distilled water in the 1 gal container cost me $1.10. I use 1/4 of that for the Escort on each watering. That's $.28  Don't be penny wise, and battery foolish.

Bat.    20 AH   Wt. pack   pack  range  Cycle  miles  miles X cycles
type     rate  Lbs. volts   Wt.  miles  life   /Lbs.  /Lbs.
T-105    217   61     96   976   59.4   754   .06086   45.89 
T-125    235   66     96  1056   64.3   650   .06089   39.58 

 Cycle Life test - T105 Wet cell battery
Capacity
100%-     .  .   .                                              -100%
    |   .   |          .     .      .       .     .
80% - .     |                                           .       - 80%
    |       |                                           |
60% -       |                                           |   .   - 60%
    |       |                                           |   | .
    |       |                                           |   |
    |       |                                           |   |    .
    |       |                                           |   |
    |       |                                           |   |      .
----------------------------------------------------------------------
Cycles     100    200    300    400    500     600     700     800
* Extrapolating for a T125, at 600 cycles you would be at 80% capacity.
Any future EV questions can be brought up and discussed on the EV List for free.

1991 Ford Escort Station Wagon purchased from Green MotorWorks in Alameda.

Curtis 1221b controller, K&W BC-20 onboard charger, 108VDC drive system, 18 T-105 batteries, 8 in front rack,

10 in rear box

I purchased this Escort EV to keep in the SF area. If it didn't get sold it was going back to the LA area (Green MotorWorks home office).

(original images) - page by: Bruce {EVangel} Parmenter EV List Editor  - 01/02