to Steve Joiner of Agilent 9/00*
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.
Note: tinted rear windows
Rear view w/ hatch open. Note: fast charger cable
Rear battery compartment w/ carpeted lid open
Plush heather colored interior
Rear seats individually fold down for additional
Passenger side front seating area
View from back seat area of front seating
Drivers view. Meters: Left - surface voltage
Right - battery current
Short throw, easy shifting 5-speed, AM-FM radio
Front view hood open,
controller in the center
View of K&W BC20 charger & vacuum pump
Heater fluid tank
& curtis controller
Front side view hood open
Front side view hood closed
Charging cord plugs into where the gas inlet was
|Escort EV *
(At cost, No profit)
Tires, shocks, brakes, transmission are all
handled the same as with as gas car. I have found
that with the reduced amount of daily driving and
less stress an EV puts on the vehicle, what could
'normal repairs' are much less often and easier
to plan for.
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
If there were either a repair/add-on/upgrade
performed to your EV, then our local qualified EV
mechanic is Mike's Auto Care
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.
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
then applying power with the accelerator is a
smooth power transfer that extends the life of
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
The onboard K&W BC20 charger uses a
standard 120VAC 20 amp outlet. With this
outlet, charging at 10amps, the EV will totlally
recharge in 10 hours (8 hours to 80% or 4 miles
per hour of charge, the final portion of the
charge cycle is slower at a lower current). With
a 120VAC 30 amp outlet with the charge set to a
20 amp charge current, the total recharge time is
6 hours (4 hours to 80% or 8 miles per hour of
charge, the final portion of the charge cycle is
slower at a lower current). If a additional Zivan
NG5 charger (using a
220VAC 40 amp outlet) were connected to the
fast charger port and the onboard charger used,
the 80% recharge time is 2 hours.
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
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,
and more. This means there is no aux 12V battery
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.
976 59.4 754
1056 64.3 650
Cycle Life test - T105 Wet cell
80% - .
. - 80%
| . - 60%
| | .
| | .
| | .
* 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.
12/99 DMV has now got the Escort in my name and
put 4 Goodyear
GLS Invicta tires (balanced),
pack is broken in, EV is ready for sale to a good
11/99-7/99 minimum use of the EV, only to
maintain it, as I wait and wait for the DMV
transfer the title.
7/99 After completion: arranged for a tow of EV
to my home (battery pack was too new to discharge
them too deeply, one should wait until they have
been broken in.
have been ordered, Clare Bell of the Women's
Racing team, will be changing out the batteries
and installing a 10 gauge cable pair from the
front battery connections to the rear interior
A SB50 connector will connect a 220V fast