This page will contain the current plan, and current state of the car. Please refer to the “Home” page for the progress and steps taken to get here.
- I haven’t updated this for awhile, everything was old news.
- Heaters have been tested and just need to be installed permanently.
- Battery box is half way there, just needs aluminium walls.
- Tablet to be disassembled and custom mounted in the center console
- EMW has created an arduino based gauge system that exceeds all of my early plans so it’s pretty easy I will be using their system!
- The rear battery box is the new big project, under the hood things are coming together.
- Battery testing and assembly is coming along, I have the last batch of batteries on order.
Parts on hand/ordered:
DC/DC converter modules for 14.4v system
Kats fluid heaters 2x 1500w
12v variable speed fluid pump for heating system
Netgain Warp 11-HV
Headway 38120S 10ah cells x12 for testing/12v replacement battery
Mes-Dea Electric vacuum pump
DC/DC converters for 90cell 96cell battery charger
Power supplies 85-264v for DC/DC battery charger
Material to prototype an aluminum battery box Now a steel framed box with aluminium walls Prototyping parts for the Arduino voltage monitoring system EMW system to be used
Soliton1 300kw DC motor controller with Evnetics throttle pot
Clutchless Aluminum coupler
Compact steel adapter plate/tube
A123 20ah cells
x120, more to follow final pack design is 288 cells (96S3P) remaining cells on order
Galaxy tab 7+ to get integrated into the center console for audio/navigation/gauges
Curb weight: ≤
Name: “944DC” I might make an emblem to replace the stock 944 badge with 944DC or 944HV to represent the DC power system or Warp 11 “HV”.
√ Motor: Netgain Warp 11-HV ~300hp, ~300ft-lbs
√ Adapter plate:
CNC machined aluminum Compact steel tube/plate with locating surfaces, no manual alignment necessary.
√ Coupler: Clutchless coupler from Charlie at evcouplerconnection.com. Taper lock with modified pulley
√ Controller: Evnetics Soliton1 300V, 1000A
√ Throttle: Evnetics hall effect throttle assembly controlled by the stock pedal & cable.
Headway 38120S 3.2v 10ah cells in a 288V A123 20ah cells in a 96S2P 96S3P 317V nominal pack with 1000A continuous peak continuous discharge .
Battery boxes: Welded/riveted aluminum/Steel with heating system
Arduino based multichannel isolated voltage monitoring system. Cell log 8’s
√ Charger: 90 96 isolated 1/4 brick DC/DC converters 22.6A @ 3.65v 23.5A @ 3.5v with 85-264v AC power supplies 3kw. Manzanita Micro PFC-20 or Zivan NG3.
√ 12v Battery:
Headway 38120S cells in a 4s3p pack to replace the heavy stock battery. A123 12v system battery.
√ DC/DC Converter: 1/4 brick modules with adjustable output 14.4v nominal 80A continuous.
Replace the power steering rack with a manual rack. Depower the existing rack.
√ Mes-Dea electric vacuum pump for the power brake booster.
√ Heater: 3kw Fluid heater using the stock heater core and controls.
√ Air Conditioning: Stock A/C system powered by
a dedicated electric motor or main motor tail shaft.
Speedometer – stock, no modifications required
Tachometer – driven by the controller
Temperature gauge – display the temperature of the heating system
Fuel guage – driven by the
controller EMW gauge system will represent battery state of charge
Voltage gauge – monitor the stock 12v system
Fuel economy – I may use this as a representation of battery current draw (or fuel economy)
Oil pressure – I’m not sure what to do with this one yet, but if I print a new scale it might be possible to use it to represent pack voltage
Dummy lights will work in much the same way, check engine will be tied to the controller and display warnings or faults.