SEVA EVUpdate Newsletter October 1995

SEVA EVUpdate Newsletter

October 1995

Presidents Message by Mark Bahlke

Well, fall is definitely in the air again. It's good to have mother nature sweep out the skies so we can breathe again, at least until we can get rid of our (societies') addiction to smoking every time we need to move around.

Of course life is moving along at a rapid clip as usual. Things are changing for us at home quite a bit. The biggest news for us is that we are expecting a new addition to our household next April! The tests show it's a boy, which we are really happy about. (Yeah I know some of you were thinking we were going to buy our second EV. Don't be too dissapointed - we'll get it yet.) We are also adjusting to having a new teenage stepchild in the house as well. When it rains it pours!

The most significant news on the EV front is the new developments in the Oil/ automaker anti EV campaign. They are upping the ante again, moving from using hired public information/lobbyist types to purchasing greater amounts of advertising time on radio, and other media to disinform the public about electric vehicles. It's a daunting task to take this on, but they are after all not telling the truth about everything. They are only acting as they have in the past, trying to exclude the competition at any cost.

A small tidbit of good news, the Santa Cruz county board of supervisors recently passed a resolution (see page 5) to support the state EV mandate, in large part to the amount of anti EV junk mail they (the supervisors) had all been getting from the Oil companies. This is good because this action, even though it is largely symbolic, can be used to try and influence other counties to pass similar resolutions. This will build a foot hold in government to support our efforts. Clare Bell newsletter editor of the national EAA Current EVents has transcribed the text of this resolution for those of us with access to the internet. I will be down loading a copy of this to my PC at home, and faxing it to our Sacramento county supervisors, also to Placer and Sutter Counties. If we could get other counties to jump on this bandwagon, that's a start. You can help here too. Get a copy of this resolution, and pass it along to the supervisors. Write some letters. Get the message OUT that we don't want to be controlled/ ditcated/manipulated by these selfish interests. We will put the resolution in the newsletter for your benefit. Don't let this opportunity go by!

On the local level, we are close to being ready for the October Ride and Drive. Preparations are almost complete from what I hear, and we should have nearly as many vehicles at this EVent as we did for the last one. Come on down to William Land Park and support your local EV group. It will be great fun. It is another opportunity to meet the public with EVs and show them that they work.

Now that fall/winter is rolling around again, it's time to move those EV projects indoors, and make plans to spend some garage time getting the EV winterized, or closer to completion. Those of you with EVs on the project board which are "in progress" should take advantage of this time to get some other members together to help get things going. We can use this time to get a whole fresh crop of EVs on the road by spring. We are a growing group!

One last note - another reminder to send in those renewalls! If it's near the end of your subscription period, we really want you to stay with us. Lets keep together so we can succeed together.

See you at the ride & drive. Mark

Monthly Meeting Minutes by Bill Dean

The meeting was opened at 10am by V.P. Tim Loree. He welcomed everyone and led the planning of the Ride & Drive, Sunday October 15. Time introduced Stan Skokan, president of Electric Vehicles, Inc, and Chairman of the national EAA.

Stan worked for Hewlitt-Packard as an electronic engineer 1969-1993. In 1975 he bought an electric motorcycle. In 1976 he converted a car, and got the first HP EV parking spot. In 1979 he designed an EV motor replacement kit. In 1987 he gave ideas to Paul McReady for his Impact. Since 1975 Stan has owned 15+ EVs and driven over 100,000 miles. He showed a 1980 photo of 3 EVs he and his wife owned at one time.

Stan put EVs in perspective with this question: Would you drive your car if the exhaust pipe were in the middle of the steering wheel?

Stan told the history of Jet Industries of Austin TX, 1979- 1984. The company started from the investments of three families. They had a market because DOE had a program in which agencies used EVs and gathered data for 5 years in exchange for half-price credit. The EVs cost 50% more than ICEs, so with the credit the EVs were a good deal. The agencies used the EVs for 5 years, then auctioned them off. Stan has resold some of them several times.

Jet made 1400 EVs in a 3-year period, an impressive record. Jet bought gliders from Ford and Chrysler, installed electric power, then sold the vehicles. Jet produced owners manuals as professional as Ford or Chrysler. Typical performance was 20 hp (40 hp peak), 0-50 mph in 23 sec.

Stan talked about his research with lead-acid batteries. One problem is stratification of electrolyte, which occurs if the battery sits unused. Regular use and charging lengthens battery life. Most batteries fail because active material falls to the bottom of the case, so the space at bottom determines life-span. When a battery overcharges, gas bubbles circulate the electrolyte, rejuvenating the battery. Cooling is a problem only if the battery is charging faster than it discharges.

Stan spoke about another problem, variability among batteries. He said that it takes 15-20 discharge cycles to determine the quality of a battery. About 20% are inadequate.

Stan said that battery life is improved by shallow discharge. The battery can go through a million cycles if near full charge. Phone company batteries last 20 years because they are always fully charged all the time. Stan recommends plugging in every chance you get. Stan points out that every house with a 220V outlet can recharge a car in two hours. However, at his own house he can charge slowly overnight. Quick recharge is important on the road. Thus Stan encourages the availability of more 220V plugs at daytime destinations.

Stan showed off a charger and a battery. The charger produces 3.0 kW DC from 220 VAC, 15A input. Output is 30A at 72V or 15A at 144V. The battery is a 50 Wh deep- discharge type, 44 pounds, capable of mounting in any position. During charging, when the battery reaches gassing voltage, the charger starts dropping current at constant voltage. When done, the charger, switches to constant current and lets the voltage rise.

Stan is building a scanner to monitor each cell in the battery. The monitor is to find the fastest charging cell. When all cells are fully charged, the charger would shut down 30 minutes later.

The meeting was adjourned at noon.

Monthly Board Minutes by Bill Dean

The SEVA board met Monday, September 11 at 730pm to discuss club business.

The first item on the agenda was the upcomming dinner with Mary Ann Chapman, for Thursday, September 14.

The Board then discussed the Ride & Drive to be held on Sunday, October 15, at Land Park. Mark will pass off the SEVA banner this week to Tony Cygan or Ruth, both of whom live near the park. The Board decided to have 200 copies of flyers to pass out: SEVA brochures; national EAA brochures; SMUD maps of recharging stations; EVIA informational flyers; driver logs. Tim Loree will contact the President of Sacramento City College about recharging opportunity. Steve Smith will design a form for drivers to declare that they have their own insurance.

The Board had a lengthy discussion about updating the SEVA brochure. Tim has the master on his computer. Arthur Cartwright and others favor putting only one option for joining: join SEVA and EAA simultaneously for $35. Mike Simpson and others favor letting new members choose to join SEVA+EAA for $35 or just local SEVA for $15. Steve and Ruth noted the complication of keeping track of members who belong to both but have different expiration dates. For now the brochure continues to have both options. The next version will update the SEVA address and phone number, will ask for e-mail address, will have the SEVA logo, and show a map of how to reach the SMUD meeting place. Tim will print out 200 for the Ride & Drive. The Board will authorize more modifications to the brochure in the near future, such as featuring pictures of members' EVs on the front.

The Board discussed other literature to hand out at events. Art likes the EVIA informational flyers. He will ask Mary Ann for permission for SEVA to copy and distribute these flyers. Mark wants the club to have input to SMUD on the map of recharging stations, in preparation by Steve Revenaugh. Mark would like to see testimonials from members regarding their favorite recharging sites. The club needs up-to-date flyers about (1) detailed information about EVs and (2) the hazards of air pollution, (3) profiles of members and their EVs. Steve and Tim will design a driver log, for ICE owners to monitor their driving habits, to see if they are compatible with EV operation. Ed Brannon suggested having two club events a month, and producing a list of events as a flyer.

Ruth announced the program for the next monthly meeting. Several members will report on the progress of their EV conversions, to share their progress and maybe get suggestions of what to do next.

Tony said that he has received many compliments about the SEVA homepage. Several people requested that he put the most recent newsletters online, instead of the current policy of keeping two months behind. Ruth moved that the club make the newsletter postings up-to-date. The motion was carried.

Steve mentioned that the EAA elections are coming soon. Tim has shown some interest in being nominated.

The meeting was adjourned at 9pm.

Hewlett Packard EVent by Dave Robinson

On Tuesday September 26, 1995, we held the first (and hopefully annual) Electric Vehicle show at Hewlett Packard's Roseville business campus. We had on display seven EVs! These included:

CSUS & McClellan's Horlacher pickup truck (Courtesy of HA Mergen and Steve Moran)
SMUD Solar assisted Horlacher (Courtesy of Patrick Kennedy and Holly Hansen)
Converted Honda Civic with ZAPI regen (Courtesy of Gregory McCrea)
ZAP bicycle & accessories (Courtesy of Isela Valdez and Darrel Singleton of Envirotech)
Converted Opel GT (Courtesy of Jim Haagen-Smidt HP)
City-El (Courtesy of Tim Hastrup HP)
Converted Fiero (Courtesy of myself)

All the exhibitors were there to set up at 10:30am and before we had set up our first browsers were coming through. By around 12:30pm HA Mergen's voice was beginning to weaken. We estimate over 500 site people came through the exhibition area located just outside the campus cafeteria. I even saw a couple of people try the ZAP! I had also arranged a TV and VCR so that I could show "The Current Solution" video and the Motor Show video featuring many famous Bay area EV'ers. By around 1:30pm the crowd had dwindled so it was time to close up.

I think everyone who attended enjoyed it, including the exhibitors. I had to keep getting my handout pile photocopied to keep up with the demand. I gave out plenty of SEVA application forms, so hopefully we might see an increase in membership in the coming months.

I would like to thank all the people who helped me put this together and participated. I think we greatly enhanced the knowledge of people at the HP site about electric vehicles. Due to it's success HP have asked me to hold another EVent next year. So, mark your calendars. Who knows; we may even try rides next year.

Upcomming SEVA Ride & Drive

We're having a Ride and Drive on Sunday, October 15th at 10:00am in Land Park. The meeting location is near Fairy Tale Town across from the Zoo. Look for the SEVA banner and other signs.

The Ride and Drive will entail the carrying of a passenger for a loop around the park boundries (2 miles). Pick-up and drop off of passengers will be at the meeting area by Fairy Tale Town. Maximum speed in the area is 35mph.

Charging will not be available at the park, but is available at Tony Cygan's and Ruth MacDougall's homes, as well as at many locations in and around downtown Sacramento (aprox 2 1/2 miles). If you will need charging please contact a board member.

This will also be a picnic, so bring some food or bring money to order take-out foods. We're going to try and start doing these types of things on a more regular basis, so be prepared ! Prepared to have fun that is !!!

PLEASE, if you have an EV, come to the EVent with your vehicle. We need as many people with electric cars, bike's, etc. to join us as possible to show the public what it's all about..

Electric Miles by Bill Dean

I may not get one of our buttons for it, but I have been racking up electronic mileage on the Infobahn. Specifically, I am referring to my online subscription to the EV list. Every day I receive electronic mail about EVs, and I can participate in discussions if I wish.

The online discussions cover all aspects relevant to EVs: the merits of various controllers; the fine points of battery maintenance; news about manufacturers' developments; news about electric buses and trucks; public reaction to EVs; what to wear on an electric bicycle; tax breaks for EV owners; political intrigue about the 1998 ZEV mandate. There is something for everybody! Posters to the list include Mark Bahlke, Tony Cygan, Bruce Parmenter, Mary Ann Chapman, and more. Plus many others whom I would never otherwise get a chance to meet.

So check it out. You will learn a lot. The EV list is the best and fastest way to be "in the know." You can ask questions and get answers from people who have already learned from the mistakes that you are contemplating. Get a second opinion, a third, a fourth.

To subscribe, send e-mail to: LISTSERV@SJSUVM1.SJSU.EDU 
with the message: "subscribe ev (your name)"    

The list server will send you further instructions.

Editors Corner by Tony Cygan

I've been thinking alot about EV's lately since I've been driving mine for about 3 weeks now. I've been thinking not only about the politics of EVs (no soapbox today), but also on the actual how-to's and what-for's of driving EVs.

The biggest thing I've noticed is that I pay alot of attention to my gauges to see how much energy I'm using. Whether I'm going to work on the highway, running errands to the grocery store, sitting at stop lights, or charging up the batteries.

I had one similar experience in a gas car. I rented a Cadillac one vacation a few years ago, and it had one of those dashboard computers in it that you could monitor your fuel consumption with. You stepped on the gas and watched the milage estimates go from cruisng at 25 mpg, to 3 mpg when taking off from a light.

I've also noticed that I spend alot of time trying to keep it charged up. Part of this is to make sure I make it a habit to opportunity charge, but also some of it is parranoia, even though i know it has plenty of range for what I use it for. I've had it ingrained into me that having virtually unlimited miles from a gas car is neccessary, when it's not. I use my EV for all my driving and have had no problems with never having enough energy to do what I want, when I want.

It'll all work out in time I'm sure, as the newness of it all wears off and it becomes just another car.

The Yellow Porsche Project by Tony Cygan

This will be the final installment of the Yellow Porsche Project. Not that the car is finished by any means, but rather it is on the road and being driven every day and I only have to 'make it pretty' for the general public.

When last I left I had made the decision to use the new 8volts Trojan batteries for the car and had designed the battery racks. So here we go --

I didn't have the expertise to weld aluminium and was in a hurry to get the car completed, so I hired out the job to a place that does welding. They used the drawing that I had made up and had the basic cases made up in a week. I then took the cases home and marked them up to get ideas on where all of the rack mounting points would be. The cases were ready two days later. I should have spent some more money and had them professionally painted (powder coating is best) but by that time I was feeling broke, so painted them myself. When I was all done in the car they went. Along the way I decided that I needed to get the car on-the-road and took a week of vacation to get the job done. My goal was the September SEVA meeting (which I made).

Since I had already started running in the low voltage wiring I finished up what I could before needing to start the high voltage cabling (of course this meant installing the batteries first). The cabling took more time than I thought it would. I made a few mistakes and had to make some cables over more than once. Some of this was do to my needing to run the cables differently than I had first wanted to, others was just not paying attention when making a cable and making it too short or putting on the wrong connector type (left, right, or straight).

I mounted my controller, contactor and shunt on a 1/4" piece of aluminium sheet which also is acting as a heat sink for the controller. This unit attached to a couple of flanges I had put on the battery box and sits between the motor and the drivers compartment firewall. It's a little hard to get at, but hopefully it will be a long time before I need access to it. My only concern is that it gets enough air flow for cooling, so I will be making up a vent to force air up over the heat sink. I also located a good spot for my potbox and had to make up an extention arm to connect up the accelerator cable

When the cabling was almost done and I was satisfied with all the other equipment installations I started to verify my wiring to make sure that there was nothing crossed and I also started a checklist of things that still needed to be done or checked to insure that I didn't cause any problems.

I reread parts of the two books that I have on EV conversions, Bob Brandts 'Build your Own Electric Vehicle' and Mike Brown's 'Convert It'. I ended up using the checklist in Mike's book when I was ready to make the last few connections and to test the vehicle for correct operations. Things like ' make sure your drive wheels are off the ground' are one of those things you just don't think of when your getting tired, yet too close to call it quits for the night.

I finally turned the wheels, in the right direction, and under electric power on Thursday night, September 7th, 1995 and my first test drive was the next day when I went around the block.

During the following week I drove the car with an ear and eye to watching for problems. I tightend bolts, replaced a wheel bearing, bleed and adjusted the brakes (regular and parking) and checked the power cables for overheating (which means they are loose). And these past two weeks I started driving the car as I would any car. I take it to work, to the store, and out to eat. In fact I have only driven my gas car once in the past two weeks. The EV is handling virutally all my needs.

As I stated earlier I still need to do a few things to the car before I will be truly finished. Painting will be done some time in the next month or so, and I do need to upgrade the suspension to bring the ride height up about 3 inches front and back. It rides like a Corvette right now (very stiff). I also need to make battery box covers, but once that's done, so is the car.

For my last words I would like to encourage anyone that is worried about not being able to convert a car to electric power to just give it a try. I had no experience before I started and made it through. It will take a little longer than you though it might, and maybe a little more money, but it will be worth it. We have alot of experience out there for you to draw on and you can have the ultimate feeling of knowing you did it yourself and that you're driving electric, without having to wait for Detroit to get of their collective butts.

See you soon. On the road and driving electric. Tony

Anti ZEV Campaign Backfires in Santa Cruz

Four Santa Cruz Supervisors received so many mailings from the anti-ZEV campaign that they passed a pro-ZEV resolution.

Board Chair Fred Keeley of the 5th District, and three other Supervisors became annoyed because they were receiving 2-3 anti ZEV-mailings a week from the California Manufacturers Association. In response, they passed Resolution 367-95, "In Support of the California Air Resources Board Mandate for Zero Emission Vehicles" Mandate". Supervisor Mardi Wormhoudt of the 3rd District motioned to propose the resolution. Supervisors voting for the resolution were 1st District, Janet K. Beautz, 2nd District, Walter J. Symons and 3rd, Mardi Wormhaoudt.

Members of the electric vehicle commu