EV Conversions for Personal Use
This is a 3-day training designed for the non-professional mechanic interested in converting a vehicle to electric power for personal use. The lecture material is presented in three modules. In general outline, this program covers the some of the same topics as the Doing EV Conversions Commercially and EV Conversion as Auto Shop Curriculum programs, but at a level appropriate for the amateur home mechanic. Handout materials include a copy of the book Convert It.
Class is limited to 12 students. Advance registration is required, and it is recommended to register as early as possible to guarantee a spot in the class. For class schedule & registration info, see the Calendar
Module #1: Owning & Using an EV. This is introductory information about EVs in general and what to expect in owning & using one on a daily basis. Topics include:
- Types of EVs – chassis types, BEVs, NEVs, HEVs, PHEVs, etc.
- Benefits – environmental, efficiency, reduced costs & maintenance, etc.
- Performance – speed, range, charging time, driving conditions, longevity
- Costs – conversion, energy, maintenance, battery replacement, incentives
- Suitable Chassis for Conversion - size, age, make, features
- AC vs. DC Drive Systems
- Registration & Insurance
- Safety – electrical, batteries, collision
- Driving & Charging – recommended techniques
- Maintenance
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Module #2: EV Components. This unit covers all of the components in a conversion, their purpose, brands available, and important features to aid in choosing the correct components to purchase. Topics include:
- Basic EV Function - Overview
- Charger & Battery Management System
- Batteries
- Contactors & Relays
- Speed & Throttle Controls
- Motors
- Transmissions & Adaptors
- DC/DC Converters
- Emergency Disconnects
- Instrumentation
- Suspension
- Tires
- Power Accessories
- Climate Control
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Module #3: Conversion Process & Troubleshooting. This unit covers all of the components in terms of placement & mounting considerations, as well as tips, tricks, and techniques to make the conversion process easier and safer. It also covers troubleshooting techniques and discussion of most likely problems encountered in EVs. Topics include:
- Philosphy of EV Conversions
- Shop Safety - Special considerations
- Special Tools & Books
- Measurements
- Stripping a Chassis for Conversion
- Body Modifications & Suspension
- Battery & Component Layout in the Vehicle
- Motor & Adaptor Installation
- Motor Mount Installation
- Battery Boxes/Racks Installation
- Throttle & Speed Controls Installation
- Emergency Disconnect Installation
- Instrumentation Installation
- Charger Installation
- High Current Cabling
- Low Current Wiring
- Final Hookup & Testing
- Troubleshooting
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