What a Concept Electric Cars and Clean Air

1
What a Concept Electric Cars and Clean Air

• C2EC2T
• Commuter Conversion Electric Car Class for
  Teachers and EV Enthusiasts
• 4th Annual Workshop
• San Diego City High School
• Coordinators Abrán Quevedo (Mr. Q) and
• Jon Karanopoulos
• July 28th to August 8th, 2008

2
The Project

• The C2EC2T workshop is a project-based
  instructional offering for teachers and electric
  vehicle enthusiasts. Workshop participants will
  learn how to convert a small ICE (Internal
  Combustion Engine) car into a NICE (No Internal
  Combustion Engine) car powered by batteries. A
  collaborative team approach will be used to
  brainstorm, plan, design, and convert the project
  car within the ten-day period.

3
DAILY ROUTINE

• PROPOSED SCHEDULE
• Workshop will be open from 730 AM to 800 AM for
  coffee and pastries. Class will start promptly at
  800 AM each morning in the classroom.
• Mr. Q and Mr. Karanopoulos will introduce the
  guest speaker for the day and the EV topic area
  to be covered. The presentation will take one
  hour and the guest presenter will stay through
  the lunch period so that individual participants
  may have an opportunity to ask questions.
• Immediately following the guest presentation, Mr.
  Q and Mr. Karanopoulos will conduct a daily
  PRE-BRIEFING of activities to be undertaken,
  including tools needed, work station location,
  and group assignments. Participants will then go
  to their designated team area to start the days
  work
• At 1130 a.m. a light (working) lunch will be
  provided in the workshop and classroom area.
• Work will stop at 230 p.m. for clean-up and
  DE-BRIEFING. The purpose of the de-briefing will
  be to evaluate each days progress and address
  any glitches and/or concerns.

4
Shop Set-up and Clean-up

• Procedures
• There will be designated areas in the shop for
  specific team objectives and functions
• Participants will be assigned to specific teams
  based on similar skills and preference
• Team leaders will be selected based on skills
  and capabilities needed to meet team objectives
• Final decisions related to all phases of the
  conversion process and applications will be made
  by the C2EC2T coordinators and team leaders
• Clean-up procedures will be the responsibility of
  all workshop participants and will be based on
  the principle of a place for everything and
  everything in its place

5
Tools and Equipment

1. Car lift
2. Engine hoist
3. Hydraulic floor jack
4. Safety stands
5. Pneumatic tools and equipment
6. Electric saber saw
7. Hand tools
8. Welding equipment
9. Safety gear and apparel
10. Specialized electric car conversion tools,
    equipment, and materials

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Daily Activities ScheduleWeek 1

• Day 1- The coordinators will welcome everyone and
  a round robin self-introduction of workshop
  participants will follow. Jon Karanopoulos, San
  Diego High School Auto Shop teacher, will give a
  tour of the auto shop. Our first presenter,
  Bill Hammons, President of the Electric Vehicle
  Association of San Diego (EVAOSD), will deliver
  his presentation on EVAOSD history and other EV
  organizations in the United States and the world.
  Mr. Hammons will also address current EV issues
  related to global warming and offer a general
  review of the latest EV technologies and EVents.
  After Mr. Hammons presentation, lunch will be
  served and ample socializing time will be
  provided on our first day together. After lunch,
  the coordinators will continue with orientation
  and distribute books, binders, workshop T-shirts,
  and homework assignments. The introduction of
  special tools required for EV conversions and
  basic EV components will follow. A safety
  presentation, consisting of (a) safety
  recommendations for EV conversions, (b) safety
  procedures, and (c) safety apparel, will also be
  given. Shop clean up procedures, designated team
  areas, selection of team leaders and members,
  team brainstorming sessions will follow.
  Participants will then be provided an opportunity
  for a hands-on activity in the use of EV car
  tools and components. Before leaving for the day,
  we all sing Puff the Mechanical Dragon, our
  theme song.
• Day 2 Mr. Q will introduce Frank Trejo,
  Regional Sales Manager of Powerstride Battery.
  Franks topic area is Deep Cycle Batteries for
  EV conversions. Mr. Q will then conduct a
  pre-briefing for the day and assign work groups
  and work areas with tasks to be completed. After
  lunch, work will continue until the clean-up and
  de-briefing period at which time book chapter
  assignment will be given out.

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Daily Activities ScheduleWeek 1

• (continued)
• Tuesday Jim Bohorquez will discuss general
  principles and dynamics related to a comparison
  of electric cars and gas cars, with a focus on
  the advantages and disadvantages of both. Topic
  areas to be covered wind resistance, operating
  costs and environmental issues. The coordinators
  will then conduct a pre-briefing for the day and
  assign work groups and work areas with tasks to
  be completed. After lunch, work will continue
  until the clean-up and de-briefing period at
  which time book chapter assignments will be given
  out. We will end by singing Puff the Mechanical
  Dragon.
• Wednesday - Frank Trejo, Regional Sales Manager
  of Powerstride Battery. Mr. Trejos topic will
  be Deep Cycle Batteries for EV conversions. The
  coordinators will then conduct a pre-briefing
  for the day and assign work groups and work areas
  with tasks to be completed. After lunch, work
  will continue until the clean-up and de-briefing
  period at which time book chapter assignments
  will be given out. We will end by singing Puff
  the Mechanical Dragon.
• Thursday Russ Lemon, retired electrical
  engineer. Mr. Lemons presentation will focus on
  technical aspects of electric car performance
  projections. The daily pre-briefing will follow
  after which shop participants will begin the
  days work. The day will end with clean-up and
  de-briefing.
• Friday Lee Campbell, retired electrical
  engineer. Mr. Campbells topic will be EV
  Conversions and Solar-assists. Mr. Campbells
  Chevy S10, which was converted two years ago,
  will be made available. Daily pre-briefing will
  follow after which shop participants will begin
  the days work. The day will end with clean-up
  and de-briefing.

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Daily Activities ScheduleWeek 2

• Monday William Rhodes, new owner of KTA
  Services, Inc. KTA Services is a major player in
  the provision of EV components for
  gas-to-electric conversions. Component parts
  will be presented and current costs indicated.
  After the presentation, we will have the
  pre-briefing and get right to work.
• Tuesday Jason Greenblatt, M.S. in Mechanical
  Engineering, and an employee of San Diego Gas
  Electric. Mr. Greenblatts topic area will be
  low-rolling resistance tires for EV applications.
  Following will be the daily pre-briefing, morning
  work, lunch break, afternoon work, debriefing and
  Puff
• Wednesday Dave Dahl, professional electrician.
  Mr. Dahl will give a presentation on his recently
  converted Chevy S10. Following will be the daily
  pre-briefing, morning work, lunch break,
  afternoon work, debriefing, and Puff
• Thursday Michael T. Kadie, EV owner. Mr. Kadie
  will address kit car conversions. A kit car will
  be present for viewing by workshop participants.
  Following will be the daily pre-briefing, morning
  work, lunch break, afternoon work, debriefing,
  and Puff
• Friday Dave Grove owner, and Bob Van Gorder
  conversion expert, will address classic car
  conversions and present a converted 1936 RR. Dave
  Cutter of the Village Energy web site will be
  talk about the media and how to address them
  regarding your future electric vehicle.
  Following will be the daily pre-briefing and
  presenting of certificates, driving the new
  electric car, sharing a final meal, followed by
  singing Puff the Mechanical Dragon one last
  time!

9
PROJECT CAR PREPARATION

• Removal of engine, gas tank and lines, exhaust
  system, radiator and hoses, and other
  miscellaneous ICE components
• Degrease and steam clean engine compartment and
  car underbody
• Brake system upgrade
• Suspension system upgrade
• Minor body work, preparation, and painting of
  project car

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Collaborative Team Area1

• Small Gauge Electrical
• Design and draw wiring diagram and determine
  component locations on project vehicle
• Assemble small gauge wiring harness with
  connectors and attach to major and minor
  components
• Install gauges, wires, relays, circuit breakers,
  and other electrical parts as specified by the
  wiring diagram
• Confirm that headlights, taillights, turn
  signals, windshield wipers, and other related
  parts are operational
• Address any additional issues regarding small
  gauge wiring as necessary

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Collaborative Team Area2

• Large Gauge Electrical
• Plan and design battery pack locations and cable
  placement
• Hook up and test electric motor prior to
  attaching it to the transmission
• Test each new 12-volt battery for surface charge
  and compare to specifications
• Install battery box in vehicle in best possible
  location for most positive and most negative
  terminals
• Perform test and service a two-year-old battery
  pack system in a similar commuter conversion car

12
Collaborative Team Area3

• Battery Pack Frame Fabrication/ Installation
• Plan and design angle iron battery pack frame for
  front and rear locations
• Fabricate plastic battery pack boxes to fit into
  angle iron frames
• Test chosen locations for battery pack frame on
  vehicle before installation in project car
• Paint frame with rust-proof primer followed by
  glossy finish paint
• Install battery packs in project car
• Install batteries into frames and secure them

13
Collaborative Teams Area4

• Adaptor Plate Installation
• Steam clean transmission housing
• Fabricate electric motor mount per KTA
  instructions and illustrations and attach to
  existing car body bracket
• Check adaptor plate for proper alignment to
  transmission and electric motor
• Remove flywheel ring gear and machine flywheel to
  reduce excess weight
• Install flywheel, clutch disc, pressure plate,
  and motor output shaft coupling per
  specifications (magic number)
• Attach motor, pressure plate, transmission, and
  place each onto engine hoist
• Install motor and transmission assembly into
  project vehicle

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Collaborative Team Area5

• Low-rolling Resistance Tires
• Locate and acquire the recommended low-rolling
  resistance tires for the project vehicle
• Present information and application charts on
  low-rolling resistance tires to workshop
  participants
• Remove existing project car tires and install new
  low-rolling resistant tires
• Test drive and chart low-rolling resistant tire
  performance such as handling and additional range
  gained
• Investigate availability and cost of aluminum
  wheels for the project vehicle

15
Collaborative Team Area6

• Power Brake
• Preassemble power brake pump and vacuum chamber
  per KTA instructions
• Fabricate brackets and base as needed
• Review placement of power brake pump assembly
  unit with coordinator before installation
• Install power brake pump assembly into project
  car
• Test the unit and make any adjustments and/or
  alterations as needed for proper operation

16
Collaborative Team Area7

• Reassembly of Project Car
• Clean and reinstall floor covering and car seats
  paint over and/or reinstall car trim
• Design and install project car logos, icons, and
  other final items as decided
• Clean and wax exterior paint, molding, and final
  prep interior
• Undertake any additional detailing as needed

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Collaborative Team Area8

• Workshop Documentation
• Take and collect photographs/videos of workshop
  participants during ten-day C2EC2T
• Assemble a multi-media presentation of C2EC2T
  workshop
• Distribute workshop presentation for participant
  portfolio and funding source documentation
• Contact local media for possible press coverage
  of C2EC2T workshop
• Brainstorm preliminary ideas and location for
  future
• C2EC2T workshops

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All Team Topics9

• Related EV Topics
• A. Roadside opportunity charging stations
• B. Electric vehicle range extenders
• C. Solar photovoltaic panels (roof racks)
• D. Battery trailers
• E. Regenerative braking systems
• F. Amtrak city to city transportation for
  electric vehicles
• G. Job development and future opportunities in
  the alternative vehicle automotive career area
• H. Entrepreneurial opportunities for electric
  vehicle component sales and for the establishment
  of professional electric vehicle conversion shops
• I. Global warming, the Greenhouse effect, the
  melting of polar icecaps and Greenland ice shield
  at an alarming rate
• J. The peaking of world oil production as of 2006
  and the need to establish alternative fuel
  sources
• K. Any additional topic areas that may be
  introduced