HOW TO BUILD AN ELECTRIC CAR covers how to build an electric …

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BAIC E150 EV Electric Cars

ELECTRIC VEHICLES — How work Electric vehicles are the simplest form of self mechanical transportation. In it most form, the drive train of an vehicle consists of a battery to an off and on switch which is attached to an motor. The electric motor the wheels.

Most electric have a more elaborate to control the amount of electricity to the motor as well as a system of to drive the wheels in a most manner. In addition to the above, powered vehicles incorporate a collector which converts energy into electricity is used to slowly recharge the

WHAT THEY CAN AND CAN NOT DO . Many have the impression that cars are pollution free and eventually replace fossil powered engines. This is rather inaccurate. The fact is at the present time, electric can not compete with main gasoline, diesel, compressed gas and other vehicles in terms of range and overall safety. In electric vehicles create in a number of

different ways. most of the electricity we use in the United is from fossil fuel power plants which pollution, though usually from the urban centers. In cases, electricity produced at power plants, though

also pose potential Solar power plants are in infancy, though they may be in sunny, areas with cloud cover. If everyone was to solar arrays on their some people may object to similar to how people objected to the 10 foot satellite dishes.

power may also offer potential to generate electricity, windmills pollute in terms of as well as noise pollution. In of this year, I drove Hamburg Germany north Denmark and passed a large of modern windmill electric The first thing that me was the loud and continuous wiring they put out.

Here in New City, there have several attempts over the 25 years to harness wind There were windmills on 10 street between Avenue A and Avenue, East 5 Street Avenue A and Avenue B and on East 9 and the Bowery. In every case, the

abandoned the windmills after a or so presumable since they not cost effective. Nevertheless a system may be useful in remote Many of the materials used in cars today are toxic.

For example the lead, which is the common element used in deep cycle electric batteries can be a serious health In the case of solar panels, of the panels are manufactured using toxic chemicals and the panels can, under the wrong pose a health

hazard. people are concerned about lines and the possible health In an electric car, you are surrounded by amounts of electro-magnetic radiation. To date,

health hazards of has not been proven. The primary facing electric vehicles is the limited storage capacity of viable batteries. The most and probably the best compromise is the deep cycle lead battery. the same type of that has been in use for electric since the 1880’s. There are batteries that do offer electrical storage capacity but at a much higher price, or overall life or low power (though higher total capacity).

Today, most cars have a range of 40 miles per charge at a speed of 35 to 45 miles per hours. Most electric cars use between 6 and 12 6 deep cycle, lead batteries. The recharging time is 8 hours and once per week, the time is 12 hours to even out the among the battery array.

cycle lead acid with proper care, can about 3 years or about 600 cycles. Factors such as temperature, moisture in the air, and how a person drives can substantially these figures. Overall, batteries are not are predictable in terms of and speed as say, a gallon of To increase range, many car have experimented by building or smaller vehicles.

Generally a or smaller vehicle can hold passengers and in most cases, not offer the safety of a larger Solar panels have used to recharge electric though there is not enough from sun light per square to directly propel a conventional pound car. It is possible to store solar energy in the to allow the car to move for a limited

SO WHY BOTHER WITH ELECTRIC Electric vehicles offer a driving experience. With low center of gravity, most

cars, offer superb as well as rapid initial

Electric motors offer continuous torque even

at speeds. This allows a to do things that

conventional fossil fuels can not do. For example, if you were to drive up to a curb with a conventional

powered car, stop and try to climb the curb, you would to rev up the motor and only then you be able to drive over

the With an electric vehicle, you be able to climb the curb out any real effort. Today, railroads around the

world use electric locomotives with the engine generating the electricity to the electric motors which turns the wheels. American tanks use the same technique. vehicles are also ideal for use in that have very gasoline costs or where fuel is simply

not available. world war two, many started to produce electric for the population. Electric cars

manufactured during the war in Spain, France, Japan and others. In my father had seen several powered and steam powered vehicles in Tokyo that citizens had converted from when gasoline was no longer

Presently, I support multi-powered or cars which utilize a of gasoline and electric motors. In vehicles, the electric power can be at low speeds or in cities limiting the of pollution in urban areas, at higher speeds, the gasoline can take over. This was actually first tried in and a number of times thereafter, but did not hold partially since is a double cost involved to the vehicle.

Electric vehicles probably have a limited market for the foreseeable future.


Electric vehicles are to build and drive, even into consideration the limitations as above. Electric vehicles are so in overall construction that can easily be built by people basic construction skills. In the form, such as in a high class, a very basic go cart can be built that can of a simple wood frame out of 2 x 4s, basic wheels, an electric a car battery and a momentary electrical to turn the electricity on and off as a gas pedal.

A sophisticated system would use a body made out of steel (or converted from an existing go-cart), with the same as the wooden cart would Simple electric vehicles as described can probably be built in two with minimal skills.

Basic frame of the Didik Sun being welded while to a basic jig.

DESIGNING: As all design projects, it is essential the designer has a clear un derstanding of the function of the final vehicle have. For example, how many will the vehicle carry? there be storage space?

or how will the vehicle be recharged? it be parked on the street? What are the regulations pertaining to electric

If the vehicle will be charged the power grid, is the available adequate for charging the vehicle?

everything of the final vehicle has written down and considered, you can to design the vehicle. With the storage capacity of batteries, it is to design the vehicle using as light weight materials can be safely incorporated into the with cost and skill in mind. It should be noted many light weight are particularly difficult to work and often times a person who is not with the particular engineering of the will actually build a that is heavier using the weight materials, than if had used heavier, but easier to use

I have seen college constructed solar powered cars using much though still questionable, fiber that probably more then if they had aluminum or steel tubing. particularly thin walled is the easiest to work with. while weighing about 60 less then steel, is difficult to weld and requires

engineering in order to fully advantage of the wight difference. can often be used for some though in an accident, it usually not offer the same protection metals offer. Steel and are by far the cheapest materials to work and this should be taken

consideration if cost of the finished is a factor.

After everything is then and only then the actual design phase In a classroom environment, I think it is important for a professor to summarize to the what materials can be used and with out suggesting a design, let the individually design their on paper as a homework assignment. At point, each member of the

As seen in this photograph, it is easier to finish all mechanical and aspects of the vehicle prior to the body. In the case of the DIDIK SUN about 500 feet of wire and 100 moving mechanical components installed prior to the body built.

should review every design and then redesign a using the new ideas gained by what other have This way new ideas can be incorporated the design. Who can predict what can be this way?

Again should compare notes and a final design should be on, perhaps by paper ballot. is a very important element should be incorporated into the In my vehicles, I make it a point to as many lights and reflectors on the as possible so that conventional car can see the vehicle from a distance.

I paint the vehicles bright for added visibility.

SKILLS . In a prototype vehicle, one must the skill of the builders. Probably any class or machine shop

build a reasonably high electric powered car. The skills that will be using off the shelf components or components includes welding metal cutting skills,

skills and general design Welding is essential if the frame of the is to be made out of steel. Surprisingly, it is easy to master basic pa rticularly if using a wire fed mig welder. Such basic mig can be purchased from mail companies such as Harbor Tools, out in California for as little as though prices can also be higher.

It will also be to have access to a metal saw. A cut off saw capable of using 12 or 14 blades is ideal. Once welding techniques are mastered, seemingly hard projects look much easier. If

the is to have a body, it is useful someone with auto repair skills be involved in the Such a person with body and painting skills can a basic body look a big

three fantasy car.

The basic materials needed to a steel framed,

electric with a body includes:

tubing. I prefer to use basic 1/2 to 1 EMT tubes. They are light easy to cut, easy to and are very inexpensive. For example, a 3/4 x

10 EMT tube at Home Depot about $2.50 in New York If you prefer, you can also purchase square steel tubes steel distributors such as Steel in New York City for low prices. The standard length of tubes form distributors is 20 or 24 feet.

Electric Motor. Though people have used ac I

much prefer to use DC motors. One to HP DC motors can

be purchased in scrap (not to be confused with junk

yards) for under They can also be purchased a

variety of surplus outlets the country.

Drive. You can use a number of to couple the

electric motor to the including sprocket gear and

BAIC E150 EV Electric Cars

pulley and belt or similar. The and belt system

is probably the system to use.

Body. are several ways to shape the One way

is to use a very large styrofoam that can be sanded

using an sander to the correct shape and covered

first with type white glue and covered with

chicken mesh to shape the body a basic metal frame.

You can cover the wire mesh fiberglass sheets,

though I cover the mesh first very thin layer of

and fabric strips to give the strength and then

cover it the fiberglass. The finish can be made

with the help of an auto expert who will smooth out

and then paint the resulting to high


Windshield. The should be made out of a substance safety in mind. While car windshields are useful, I have them to be generally too heavy for my Instead, I prefer to use unbreakable type plastic.

I normally use the thick lexan and for strength, the windscreen so that it is curved. It is possible to mould the windscreen either a vacuum or compression though this requires a high degree of construction

When designing an electric it is important to consider exactly how the will be used. In the case of the SUN SHARK, it was designed to be able to go a standard 28 doorway.

Electric and switches can be purchased at most supply houses.

CONSTRUCTION : the vehicle has been designed on and the components purchased, you can proceed the actual construction. Safety never be compromised. Always ear plugs, face shield, protective clothing and work in a ventilated, properly lighted

First cut out the immediate metal parts and weld them I have found that a store type rolling rack can be utilized as a welding jig the use of vice grips to hold the that is being welded After the frame has been together add the steering mechanism and dr ive components. Before the body can be on to the

vehicle, it is essential that the is in complete working order. the body has been built, it is more

DIDIK SUN SHARK the solar panel installed.

to make possible modifications to the components. Initial test should not be conducted on public

but rather on private property, at the possible speed. As with all it will probably be necessary to minor and possibly major before the vehicle is ready for use. No matter how much is made in

designing the vehicle, one can predict the effects of every design feature.

Construction of a vehicle, capable of holding two should not take more 60 hours of actual construction though it may take as little as 25

LEGAL REQUIREMENTS The federal as well as all states have rule for motor vehicles Almost all states have provisions for electric cars. most states allow powered vehicles with assists to operate on local without having to be registered. some

states have regulations that are easier to to for slow moving vehicles or vehicles such as snow or all terrain vehicles. These may be useful to know when the vehicle.

Also go to Didik which describes how to build a 2 electric vehicle in only 14

Press CTRL D now, to this site

BAIC E150 EV Electric Cars
BAIC E150 EV Electric Cars
BAIC E150 EV Electric Cars


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