ELECTRIC VEHICLE PATRICK COLLINS & JARRED LORUSSO August 28, 2009- January 22, 2010.

ELECTRIC VEHICLEELECTRIC VEHICLE

PATRICK COLLINSPATRICK COLLINS&&

JARRED LORUSSOJARRED LORUSSO

August 28, 2009- January 22, 2010August 28, 2009- January 22, 2010

Electric Vehicle – Mission Statement:Electric Vehicle – Mission Statement:

• In an effort to save the environment and reduce our In an effort to save the environment and reduce our dependence on foreign oil, we wanted to convert a gasoline dependence on foreign oil, we wanted to convert a gasoline powered car into an electric vehicle. powered car into an electric vehicle.

• With the support of Mr. Mongillio, the Macari fund and Jim With the support of Mr. Mongillio, the Macari fund and Jim Lynch (mechanic for Lorusso Construction) as well as Bob Lynch (mechanic for Lorusso Construction) as well as Bob and Bryan from Electric Vehicle of America (EVA), we and Bryan from Electric Vehicle of America (EVA), we converted a 1998 Saturn gas powered vehicle into an converted a 1998 Saturn gas powered vehicle into an electric vehicle.electric vehicle.

Overview On The Importance of Electric Overview On The Importance of Electric Vehicles:Vehicles:

The Importance of Electric Vehicles:The Importance of Electric Vehicles:

• Gas is a scarce, natural resource.Gas is a scarce, natural resource.

• Electricity is cheaper than gas. Electricity can come from Electricity is cheaper than gas. Electricity can come from renewable resources such as solar and wind power.renewable resources such as solar and wind power.

• Electric cars pollute less than gas-powered cars.Electric cars pollute less than gas-powered cars.

• Electric cars are much more reliable and require less Electric cars are much more reliable and require less maintenance than gas-powered cars. You don't even need maintenance than gas-powered cars. You don't even need to get your oil changed every 3,000 miles!to get your oil changed every 3,000 miles!

• By using domestically-generated electricity rather than By using domestically-generated electricity rather than relying on foreign oil, the USA can become more relying on foreign oil, the USA can become more independent.independent.

Source: www.whokilledtheelectriccar.com

US Gasoline Consumption & Reliance On US Gasoline Consumption & Reliance On Imports Has Dramatically Increased:Imports Has Dramatically Increased:

US consumption Increasing Reliance

on importsdramaticallyIncreasing.

US productiondramaticallyDecreasing

The Problems With Gasoline Powered The Problems With Gasoline Powered Vehicles:Vehicles:

1.1. Gasoline Is A Scarce Gasoline Is A Scarce Resource:Resource:– Production ShortagesProduction Shortages

• Alaskan oil has reduced.Alaskan oil has reduced.

• US Coastal oil impactedUS Coastal oil impacted by hurricanes. by hurricanes.

– Oil Spills can occurOil Spills can occur– Gasoline Is ExpensiveGasoline Is Expensive

2.2. Heavy Reliance On ImportsHeavy Reliance On Imports::– US only manufactures 34% of US only manufactures 34% of

gasoline needed in US.gasoline needed in US.– Heavy reliance on foreign countries.Heavy reliance on foreign countries.– Pricing is uncontrollablePricing is uncontrollable– Future availability may be limited Future availability may be limited

especially with 3especially with 3rdrd world country world country expansion.expansion.

3.3. Creates Smog & Ozone in Big Creates Smog & Ozone in Big CitiesCities::– Nitrogen oxides, the main source of urban Nitrogen oxides, the main source of urban

smogsmog

– Unburned hydrocarbons, the main source of Unburned hydrocarbons, the main source of

urban urban ozoneozone

4.4. Creates Greenhouse Gases Creates Greenhouse Gases::- Carbon monoxide, a poisonous gas Carbon monoxide, a poisonous gas

is one of the major “Greenhouse is one of the major “Greenhouse Gases”.Gases”.

- Greenhouse effects the planet, rising Greenhouse effects the planet, rising sea levels, flooding, etc.sea levels, flooding, etc.

– The main source (95%) of carbon monoxide in our air is from vehicle emissions. (Per EPA studies)

http://science.howstuffworks.com/ozone-pollution.htm

http://science.howstuffworks.com/question162.htm

Accidents Happen: Oil Spills:Accidents Happen: Oil Spills:

• On January 23, 2010, an oil-spillOn January 23, 2010, an oil-spilloccurred in Texas impacting wildlife areas.occurred in Texas impacting wildlife areas.

The U.S. Coast Guard said about The U.S. Coast Guard said about 462,000 gallons 462,000 gallons - or 11,000 barrels- or 11,000 barrels - of oil spilled into the water - of oil spilled into the water Saturday when an 800-foot tanker collided with a Saturday when an 800-foot tanker collided with a towing vessel pushing two barges near Port Arthur, towing vessel pushing two barges near Port Arthur, about 90 miles east of Houston. about 90 miles east of Houston.

It was the largest oil spill in Texas since 1994, when It was the largest oil spill in Texas since 1994, when 4.3 million gallons of crude oil4.3 million gallons of crude oil spilled about 60 spilled about 60 miles off Galvestonmiles off Galveston . .

• One of the largest oil spills happened in Alaska in One of the largest oil spills happened in Alaska in 1989 when the Exxon Valdez ship spilled 1989 when the Exxon Valdez ship spilled 10.8 10.8 million gallons of crude oil.million gallons of crude oil. It is considered one It is considered one of the most devastating human-caused of the most devastating human-caused environmental disasters ever to occur at sea environmental disasters ever to occur at sea

Port Arthur Oil Spill- 01/23/10

Exxon Valdez 1989 Accidentresulted in oil pooling at shore.

Electric Vehicles Save Gas & Money;Electric Vehicles Save Gas & Money;--Over $18,000 potential savings:Over $18,000 potential savings:

Electric Vehicles Have A Few Downsides:Electric Vehicles Have A Few Downsides:

• Batteries need to be charged.Batteries need to be charged.

• Car can not be used when batteries are being charged.Car can not be used when batteries are being charged.

• Car can only go 40 Miles between charges.Car can only go 40 Miles between charges.

• Battery disposal needs to be carefully managed.Battery disposal needs to be carefully managed.

Our ProjectOur Project::

• The objective of our project is to convert a gas-powered The objective of our project is to convert a gas-powered vehicle into an electric vehicle.vehicle into an electric vehicle.

Our Project: The Electric Vehicle Process:Our Project: The Electric Vehicle Process:

• Research internet for electric vehicle information. March- June 2009- 3 Research internet for electric vehicle information. March- June 2009- 3 hourshours

• Contacted [EVA] to discuss parameters of project and cost estimate. July Contacted [EVA] to discuss parameters of project and cost estimate. July 2009 – 1 hour2009 – 1 hour

• Proposed project to [Mr. Mongillo] Got approval from Macari fund. August Proposed project to [Mr. Mongillo] Got approval from Macari fund. August 2009- 2 hours2009- 2 hours

• Researched automobiles which fit [EVA] specifications. August 2009- 2 Researched automobiles which fit [EVA] specifications. August 2009- 2 hourshours

• Put in offer for 1995 Ford Escort, We were out bid. August 25, 2009Put in offer for 1995 Ford Escort, We were out bid. August 25, 2009

• Purchased 1998 Saturn from Ebelings Auto. August 28, 2009 for Purchased 1998 Saturn from Ebelings Auto. August 28, 2009 for $1,750.00- 2 hours$1,750.00- 2 hours

Electric Vehicle-Decision Making:Electric Vehicle-Decision Making:

• The car ran great!The car ran great!

• The body of the car was in The body of the car was in good condition.good condition.

• It was under 3,000 lbs gross It was under 3,000 lbs gross body weight.body weight.

• It had a standard It had a standard transmission.transmission.

• It fit the criteria for an It fit the criteria for an eligible car to convert to an eligible car to convert to an Electric Vehicle.Electric Vehicle.

Electric Vehicle Conversion Budget:Electric Vehicle Conversion Budget:

• Cost of Car- Cost of Car- $1,750$1,750• Cost of Electric Motor- Cost of Electric Motor- $1,550$1,550• Cost of Controller- Cost of Controller- $1,495$1,495• Clutch less Transmission- Clutch less Transmission- $725$725• Clutch plates and all bracketsClutch plates and all brackets $400$400• 10 Batteries10 Batteries $2,250$2,250• Battery ChargerBattery Charger $1,030$1,030• Battery Cables, Terminals, Heat Shrink Battery Cables, Terminals, Heat Shrink $400$400• Inside InstrumentsInside Instruments $225$225• Fuse Systems- Fuse Systems- $225$225• Total Cost of Parts- Total Cost of Parts- $10,050$10,050

Mr. Lorusso donated his garage & time of mechanics PRICELESS- Mr. Lorusso donated his garage & time of mechanics PRICELESS- Thank You!!Thank You!!

Electric Vehicle Conversion: Company UsedElectric Vehicle Conversion: Company Used

• ELECTRIC VEHICLE OF AMERICA is a company in NH which ELECTRIC VEHICLE OF AMERICA is a company in NH which has helped people convert over 1,000 gas-powered vehicles has helped people convert over 1,000 gas-powered vehicles to electric vehicles . We called them many times for help. to electric vehicles . We called them many times for help.

• Worked with Bob & Bryan (EVA) sending specifications of Worked with Bob & Bryan (EVA) sending specifications of the automobile to determine total budget for the project- 2 the automobile to determine total budget for the project- 2 hourshours

• Some of the cars converted can be seen on the following Some of the cars converted can be seen on the following pages.pages.

Electric Vehicle Conversion:Electric Vehicle Conversion:

Electric Car(s) Converted by EVAElectric Car(s) Converted by EVA


• Other Electric Vehicle(s) Converted by EVAOther Electric Vehicle(s) Converted by EVA

Electric Vehicle – Motor Removal:Electric Vehicle – Motor Removal:

• This is the look of the This is the look of the engine before we removed engine before we removed it.it.

• We had to remove the We had to remove the muffler, radiator, muffler, radiator, alternator, air conditioner. alternator, air conditioner. – About 3 hours– About 3 hours

Electric Vehicle: Engine RemovalElectric Vehicle: Engine Removal

• Jarred, Patrick & Jim removed Jarred, Patrick & Jim removed engine from car- November engine from car- November 1414thth- - 5 hours5 hours

• What made removing the What made removing the engine much easier was a car engine much easier was a car lift. We were able to loosen lift. We were able to loosen bolts from underneath the car bolts from underneath the car instead of laying on our backs.instead of laying on our backs.


• In order to remove the In order to remove the engine the front wheels engine the front wheels and the transmission had and the transmission had to be removed first to to be removed first to allow us to get at the allow us to get at the

motor mountsmotor mounts..


• We used an engine hoist to We used an engine hoist to pull the engine out of the pull the engine out of the car.car.

• The total process of Jarred, The total process of Jarred, Pat, Jim, Matt & Gerry took Pat, Jim, Matt & Gerry took 5 hours.5 hours.

Electric Vehicle-Next StepsElectric Vehicle-Next Steps

• The motor is out of the car.The motor is out of the car.

• The wheels and The wheels and transmission are on the transmission are on the ground.ground.

• NOW WHAT???NOW WHAT???

• We need help from EVA-We need help from EVA-


• We had to take the motor We had to take the motor and transmission and transmission measurements and send measurements and send them to EVA. them to EVA.

• EVA fabricated a clutch EVA fabricated a clutch plate for us. Mr. Collins plate for us. Mr. Collins drove to NH to pick up all drove to NH to pick up all of the parts. 4 Hoursof the parts. 4 Hours


• Once the engine and Once the engine and transmission were out, we transmission were out, we had to install the clutch had to install the clutch plate which got connected plate which got connected to the new engine. to the new engine.

• The clutch plate works with The clutch plate works with the transmission to shift the transmission to shift the gears.the gears.


• We needed to use a drill We needed to use a drill press to make very precise press to make very precise holes where the clutch holes where the clutch plate connected to the plate connected to the motor.motor.

Electric Vehicle: Engine Removal:Electric Vehicle: Engine Removal:

• Our car has a clutchless Our car has a clutchless transmission. transmission.

• This means that instead of This means that instead of using a clutch to switch the using a clutch to switch the gears you wait for a certain gears you wait for a certain speed to switch gears.speed to switch gears.


• The clutch plate was a 12” x The clutch plate was a 12” x 12” x 1” piece of metal. 12” x 1” piece of metal.

• It needed to be cut with a It needed to be cut with a laser saw. laser saw.

• The laser saw cut metal with The laser saw cut metal with a 1200 degree laser. The a 1200 degree laser. The laser was very precise. laser was very precise.

• Then we used a ban saw to Then we used a ban saw to smooth out the rough edges.smooth out the rough edges.

Electric Vehicle- Next Steps??Electric Vehicle- Next Steps??

• The steps to measure the The steps to measure the clutch plate drill the holes clutch plate drill the holes and get the motor installed and get the motor installed was done over 3 Saturdays was done over 3 Saturdays in November and in November and December- Approximately December- Approximately 15 hours.15 hours.

• Jarred & Pat are pondering Jarred & Pat are pondering the next steps.the next steps.

Electric Vehicle: Engine ConversionElectric Vehicle: Engine Conversion

• The motor then gets The motor then gets installed and the wheels installed and the wheels and transmission get and transmission get reinstalled.reinstalled.

• The clutch plate which we The clutch plate which we cut is the big piece of cut is the big piece of metal on the right side of metal on the right side of the motor.the motor.

• The clutch plate and motor The clutch plate and motor mounts hold the motor mounts hold the motor straight. 5 hoursstraight. 5 hours

Electric Vehicle: Battery ConversionElectric Vehicle: Battery Conversion

• The car is powered by 10 The car is powered by 10 batteries. batteries.

• There will be 6 batteries in There will be 6 batteries in the trunk, and 4 in the the trunk, and 4 in the front of the car for proper front of the car for proper weight distribution.weight distribution.


• Creative battery holders Creative battery holders were made. This one is in a were made. This one is in a wheel well and on a hinge. wheel well and on a hinge. 3 hours3 hours


• This is where the radiator This is where the radiator was removed.was removed.

• A metal table was made to A metal table was made to hold 2 batteries in the front hold 2 batteries in the front of the car. 4 hours to of the car. 4 hours to fabricatefabricate


• The trunk was measured The trunk was measured and a metal reinforced and a metal reinforced plate was created to hold 6 plate was created to hold 6 batteries.batteries.

• Each battery weighs 70 Each battery weighs 70 lbs. or 420 lbs in the trunk lbs. or 420 lbs in the trunk and 280 lbs in the front of and 280 lbs in the front of the car plus the weight of the car plus the weight of the motor, transmission the motor, transmission and front end of the car.and front end of the car.

• 3 hours to fabricate3 hours to fabricate..


• This is Curtis who did the This is Curtis who did the fabricating.fabricating.

• Patrick & Jarred helped Patrick & Jarred helped measure and cut the metal measure and cut the metal pieces.pieces.

• Curtis welded the pieces Curtis welded the pieces together.together.

• The total fabrication The total fabrication process took 10 hours.process took 10 hours.


• It is critical to get two It is critical to get two coats of paint on all of the coats of paint on all of the welded metal to avoid welded metal to avoid rusting.rusting.

• Jarred painted the two Jarred painted the two wheel wells.wheel wells.


• Patrick painted the battery Patrick painted the battery holder for the trunk. This holder for the trunk. This was done to protect from was done to protect from corrosion-not weather.corrosion-not weather.

• Patrick painted the holder Patrick painted the holder under the hood as well.under the hood as well.

• All painting- 2 hoursAll painting- 2 hours


• Once the paint dried, the Once the paint dried, the fabricated metal had to be fabricated metal had to be secured into the trunk with secured into the trunk with lag bolts to hold the tray in lag bolts to hold the tray in place.place.

• This process took 1 hour.This process took 1 hour.


• We had to make cables to We had to make cables to run from battery to run from battery to battery.battery.

• We needed to crimp the We needed to crimp the battery terminal onto the battery terminal onto the wire.wire.

• 24 wires 2 terminals for 24 wires 2 terminals for each wire. 1 houreach wire. 1 hour


• We had to use small We had to use small crimpers to crimp the crimpers to crimp the small battery terminals small battery terminals and large crimpers to and large crimpers to crimp the large terminals.crimp the large terminals.

• 10 batteries-2 terminals 10 batteries-2 terminals each battery; 2 ends to each battery; 2 ends to each cable 40 terminals. each cable 40 terminals.

• Took about 2 hours to Took about 2 hours to make.make.


• Mr. Lorusso is teaching Pat Mr. Lorusso is teaching Pat & Jarred how to shrink & Jarred how to shrink rubber around the battery rubber around the battery terminals.terminals.


• Once we crimped the Once we crimped the battery terminal, we had to battery terminal, we had to shrink rubber around each shrink rubber around each terminal to protect it from terminal to protect it from moisture getting into the moisture getting into the battery terminal.battery terminal.

• Took about 1 hour to Took about 1 hour to shrink all cables.shrink all cables.


• Mr. Lorusso, Jimmy and Mr. Mr. Lorusso, Jimmy and Mr. Stewart from the battery Stewart from the battery company use a volt meter company use a volt meter to connect the batteries to connect the batteries together to get maximum together to get maximum power.power.

• Took about 1 hour.Took about 1 hour.


• Once the tray was in place, Once the tray was in place, the batteries were installed the batteries were installed with foam insulation to with foam insulation to protect the batteries in the protect the batteries in the event of an accident.event of an accident.

• Mr. Lorusso is measuring Mr. Lorusso is measuring for stabilizer bars.for stabilizer bars.

• This took 2 hoursThis took 2 hours


• These are the two batteries These are the two batteries which are in the front of the which are in the front of the vehicle.vehicle.

• There are two batteries which There are two batteries which are also on each wheel well.are also on each wheel well.

• Each battery is connected by Each battery is connected by the cables and terminals the cables and terminals which we made. One cable which we made. One cable goes from the positive goes from the positive terminal to the negative terminal to the negative terminal. terminal.

• Then the next cable takes the Then the next cable takes the power to the next battery.power to the next battery.


• This is the battery tray with all This is the battery tray with all of the cables connected and of the cables connected and the vertical stabilizer bars in the vertical stabilizer bars in place.place.

• The red cable on the side The red cable on the side connects the batteries from connects the batteries from the back of the car to the front. the back of the car to the front.

• It connects under the car using It connects under the car using a plastic sleeve. a plastic sleeve.

• Running and connecting cables Running and connecting cables took 4 hours.took 4 hours.


• This is the side view of the This is the side view of the car with the two front car with the two front batteries connected.batteries connected.

• The heavy cable is the The heavy cable is the front to back cable front to back cable connecting the batteries connecting the batteries from the trunk to the hood.from the trunk to the hood.


• There is a fire proof board There is a fire proof board which is on a hinge. These which is on a hinge. These are all of the components are all of the components which run the car.which run the car.

• The large black box is the The large black box is the controller which talks to controller which talks to the batteries and the the batteries and the motor.motor.

• Fabricating board and Fabricating board and installing components 4 installing components 4 hours.hours.


• The throttle is on the left The throttle is on the left side. This controls the side. This controls the speed of the car.speed of the car.

• The battery on the right The battery on the right side of the car. This is the side of the car. This is the regular car battery which regular car battery which controls the horn, radio controls the horn, radio and wipers.and wipers.


• The alternator of the car The alternator of the car was removed with the was removed with the motor. There is a DC-DC motor. There is a DC-DC converter which runs off of converter which runs off of the other batteries which the other batteries which charges the car battery.charges the car battery.

Electric Car Conversion:Electric Car Conversion:

• This is the board with the This is the board with the hinge up.hinge up.

• The red cables connect the The red cables connect the controller to the motor.controller to the motor.

Electric Vehicle Conversion-What’s Next??Electric Vehicle Conversion-What’s Next??

• The battery charger needs The battery charger needs to be connected.to be connected.

• We are going to install it We are going to install it by the gas tank. You will by the gas tank. You will have to open the gas tank have to open the gas tank to plug in the batteries. 2 to plug in the batteries. 2 hourshours


• To register the car, there To register the car, there needs to be a stencil that needs to be a stencil that shows this is an electric shows this is an electric vehicle- 290 Auto Body to vehicle- 290 Auto Body to complete along with fixing complete along with fixing the scratch on drivers the scratch on drivers door- 6 hoursdoor- 6 hours

• We are going to replace We are going to replace the drivers seat because the drivers seat because there is a rip in it- 2 hoursthere is a rip in it- 2 hours

• We need to install the We need to install the gauges to show the power gauges to show the power in the batteries – 4 hoursin the batteries – 4 hours


• Wash & polish the car Wash & polish the car inside and out- 3 hours.inside and out- 3 hours.

• Charge the batteries for 8 Charge the batteries for 8 hours- Drive Car for 10 hours- Drive Car for 10 miles and recharge miles and recharge batteries 3 times.batteries 3 times.

• Bring Car to Auction!Bring Car to Auction!

Electric Vehicle-TIME LINE RECAP:Electric Vehicle-TIME LINE RECAP:

• Decision Preparation- Decision Preparation- 3 hours3 hours• Project Proposal-Project Proposal- 3 hours3 hours• Research/buy carResearch/buy car 4 hours4 hours• Budget proposalBudget proposal 2 hours2 hours• Pre Engine RemovalPre Engine Removal 3 hours3 hours• Engine RemovalEngine Removal 5 hours5 hours• Pick up Parts/clutch platePick up Parts/clutch plate 4 hours4 hours• Clutch Plate Preparation/installClutch Plate Preparation/install 15 hours15 hours• Stabilize MotorStabilize Motor 5 hours5 hours• Battery holder fabrication/weldingBattery holder fabrication/welding 10 hours10 hours• Painting & Installing Battery holdersPainting & Installing Battery holders 3 3

hourshours

Electric Vehicle-TIME LINE RECAP:Electric Vehicle-TIME LINE RECAP:

• Cutting & Crimping CablesCutting & Crimping Cables 4 hours4 hours• Battery InstallationBattery Installation 3 hours3 hours• Cable Connection (All)Cable Connection (All) 4 hours4 hours• Board FabricationBoard Fabrication 2 hours2 hours• Assemble Components on boardAssemble Components on board 2 hours2 hours• Install Battery ChargerInstall Battery Charger 2 hours2 hours• Stencil & Body Work Stencil & Body Work 6 hours6 hours• Replace Drivers SeatReplace Drivers Seat 2 hours2 hours• Install gaugesInstall gauges 4 hours4 hours• Clean & Polish carClean & Polish car 3 hours3 hours

• TOTAL TIME ALLOCATED TO CONVERSIONTOTAL TIME ALLOCATED TO CONVERSION 86 86 HOURSHOURS

Electric Vehicle- What Did We Learn?Electric Vehicle- What Did We Learn?

• We learned to use a step by step process.We learned to use a step by step process.

• We learned how to use ratchets, lifts, engine hoists, blow torches, We learned how to use ratchets, lifts, engine hoists, blow torches, laser saws, band saws, and all other types of cool tools.laser saws, band saws, and all other types of cool tools.

• We learned that no mechanical project is too big as long as you have We learned that no mechanical project is too big as long as you have great mechanics.great mechanics.

• Electric Vehicles will really help save our environment. Electric Vehicles will really help save our environment.

• Electric Vehicles can save thousands of dollars in fuel costs. Electric Vehicles can save thousands of dollars in fuel costs.

• The United States should continue to invest in alternative fuel sources.The United States should continue to invest in alternative fuel sources.

• Small environment changes will make a difference. We can make a Small environment changes will make a difference. We can make a difference! We did make a difference.difference! We did make a difference.

Electric Vehicle- Thank YouElectric Vehicle- Thank You

• To Mr. Mongillo for inspiring us with the idea.To Mr. Mongillo for inspiring us with the idea.

• The Macari Fund & Sister Martha for helping us out The Macari Fund & Sister Martha for helping us out financially (Our parents too for making up the difference financially (Our parents too for making up the difference with money and time.)with money and time.)

• EVA for providing us technical support.EVA for providing us technical support.

• Lorusso Corporation for providing us garage space and Lorusso Corporation for providing us garage space and great mechanics like Jimmy & Curtis.great mechanics like Jimmy & Curtis.

• 290 Auto Body for stenciling and repairing the door and 290 Auto Body for stenciling and repairing the door and searching salvage yards for the drivers door.searching salvage yards for the drivers door.

Electric Vehicle ConversionElectric Vehicle Conversion

THANK YOUTHANK YOU

The future really is in our hands!

ELECTRIC VEHICLE PATRICK COLLINS & JARRED LORUSSO August 28, 2009- January 22, 2010.

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Transcript of ELECTRIC VEHICLE PATRICK COLLINS & JARRED LORUSSO August 28, 2009- January 22, 2010.