Longest distance on record!

Since I installed my lithiums, I knew my range was theoretically longer (~50 miles estimated with my style of driving), but the longest I had traveled was 26 miles. I pushed it a little farther today, driving from Edmonds to Bothell (morning commute), not charging at work, then driving home via a longer route, through Mukilteo (almost into Everett), then back to Edmonds.

The drive data:
33.7 miles
64 Ah used

Longest distance driven by me on a single charge!

No particular negative issues, and the cells performed very well during this hilly, speedy drive, even at the end of the run - no compromised performance that I could tell. Not surprising for lithiums, but I had to test it to be sure.

This data point (33.7 mi/64Ah = ~0.53 mi/Ah) seems to corroborate earlier data points that my range with the new cells is ~50 miles with aggressive driving!

Fuse replaced, old wheels back on!

After replacing the HV fuse with a beefier variety, I decided to go back to my ol' reliable 14" LRR Sumitomos, which not only are more efficient than my heavier 'pimp-ride' tires but also handle much nicer - must be the fact that they are narrower (185s, not 205s).

And so I go, unfazed in the face of my temporary fuse setback, and proceed to get back on my Electric Horse. After all, that's what this is about right? Learning from my design flaws.

Onward! I start driving Electro again tomorrow.

'Pop' goes the HV fuse!

I knew I was asking for it.

I have a rather 'close shave' HV fuse - a 200A semiconductor Bussman - in the lithium battery pack. It's rated for 200A continuous, but can tolerate more for finite periods of time, depending on the time duration. This is what is referred to as the I-T curve. For example, the fuse will open at 400A for 10 sec, 600A for 6 sec... you get the picture.

I have been driving Electro with my battery pack for a month. 'Why did the fuse blow today?' you might ask. Well, follow along on the path with me! Each step added more instantaneous torque, which added instantaneous current draw.

1) Install the battery pack, with a nomimal HV fuse, and drive rather conservatively in city driving.
2) Install the new transmission - all of a sudden, starting in 1st gear is really fun!
3) I drive less conservatively on hills after installing my e-meter and seeing that hills don't take that much energy to drive up.
4) Sound-proof for freeway driving. Freeway driving is a lot of fun now! Especially at higher speeds.
5) Install cool-looking (but less efficient and heavier) wheels on Electro. Suddenly first gear starting from a stop requires more torque/current than before.

All these factors combined to hit my fuse today. Starting my drive home from work, I entered the *freeway* on-ramp from a metering light, *rapidly accelerating to freeway speed*, *on an on-ramp that is up a hill*, and *with heavier wheels*. POP! I got a tow truck ride home.

I will be searching for a more lenient fuse (300A perhaps) that can tolerate my driving style. In the meantime, I have reinstalled a safety fuse (500A semiconductor) in the slot, so that in the event of a calamity/short circuit it will still protect me but may not protect the pack.

Live and learn!

Doin' a lot of freeway driving!

Ever since I installed some (badly needed) soundproofing around the rear battery box, I have found that freeway driving is a lot less like driving in a wind tunnel. Go figure. So today I not only drove to work using the 'modern way' (I-5 to I-405), I found Electro handled great at speeds exceeding 70 MPH.

I was so gutsy with this new confidence that I decided to push range as well. So I drove down to the Seattle EV Association meeting near the U District and back to Edmonds, on the freeway (60-70 MPH both ways) without recharging, for a total distance of around 26 miles.

Electro's e-meter reported using 47 Ah for the trip, which is pretty close to half the capacity of my 100Ah pack.

So empirical data supports my initial theoretical estimate of 50 mile range, driving aggressively (as I usually do). Driving a little less aggressively, I could push this new range to 60 or 70 miles, but then I'd have no fun. If anyone knows me, they know I like to spin the tires :)

Silent running!

I installed the TBS e-meter this last week, and it works well! Gives me Amp-hours used, % traction pack depleted, instantaneous amp draw, pack voltage, the works. Even historical data.

Just for grins, I pulled the fuses for the brake booster and DC/DC cooling fans, which are both optional devices at this point. A little-known fact - these are the noisiest things in the car. When I disabled them, I essentially run silently, minus the subtle motor noise. What fun! My brakes are a little stiff because of the lack of a booster, but I think I like driving like this (think old manual VW brakes).

Next up... soundproofing the back cargo area around the rear battery box.

Freeway drive this morning

Since I installed the lithium batts, I have been testing in city driving, but I knew I did have the increased torque and top speed to drive on the freeway. So this morning I went for a test drive on I-5. Worked great! But I forgot that old cars have a LOT of internal noise on the freeway. It was like a wind tunnel in there! At some point I have to work on some soundproofing!

Transmission replacement complete!

Picked up Electro from the VW shop today. No major problems with the tranny replacement. Drove it home, didn't notice any difference. The real difference is that this one won't leak, and has a life ahead of it! Also the 10:1 prescaler for my new fangled E-meter is enroute from Australia, should be here in a few days! Time for some driving videos this weekend!