Bonus gear discovered!

During driving of Electro over the last few months, I had noticed two minor problems with the gear shift pattern. First, the Reverse (up/left) was dangerously close to First (up/mostly left), and I even though I theoretically had 5 gears in the transmission, I could never get into Fifth. This was becoming more of a problem as I started approaching freeway speeds on my commute last week.

This weekend I set about looking through the VW shift linkage and connections, and found that my shifting rod part of the linkage (the rod running between the shifter and the engine compartment) was slightly misaligned. Its connected via a simple clamp and bolt, so after loosening, adjusting and retightening the clamp, I not only retrieved access to Fifth, but also fixed Reverse such that I need to push down on the shifter before up/left. Two problems fixed with one correction!

It's a little cold and rainy this week, so probably no commute trips with Electro (still has leaky roof), but I am considering taking some video of trips soon for the blog.

First week of commuting with Electro

I finished my first week of commuting to work with Electro - no issues! I have found a great non-freeway route as I break in the EV, and the distance is around 12.5 miles. I can recharge at work, so this is a great distance to break the batteries in on.

Clint Eastwood talks EVs on Letterman!

http://www.youtube.com/watch?v=QBmB32cfD4w&feature=related

Fascinating.

First full commute with Electro - success

I just returned from driving Electro to work today (10-12 miles each way depending on route). Lots of coworkers had wanted to see this electric jalopy - my one hour show at lunch felt a lot like an entry in a car show... hood up, explaining the car stats, people starting to put their fingers where they shouldn't =). During the commute, I was again concerned about Heartbreak Hill, a fairly steep hill that lasts about 1/2 mile. It is by far the biggest ass-kicker hill for any vehicle in the area, electric or otherwise. Electro attacked it like a champ, at a slower but respectable speed. Which reminds me - in my commute I don't go on the freeway (yet) but I do maintain a healthy speed of between 35-40 MPH. Electro really zips along nicely.

The facilities guy at my work says he bought an 'EV charging station' sign, and will post it on the light pole where I plug in during the day. Awesome!

Test drive #5: Heartbreak hill

To test out the torque capabilities on my 'lead sled', I drove it on a hilly 18-19 mile course, which includes a brutal 1/2 mile steep uphill climb halfway in. Electro made it back home with charge to spare, but on the brutal hill Electro had to be in second gear and ran at 25-30 mph. Reasonable, but I think I was hitting my Zilla battery current limit. I will be looking at increasing this limit from 600A to either 700A or 800A for short term torque needs.

You knew it was bound to happen! There will be an electric version of
the Smart Car soon. A partnership between Tesla and Daimler:

http://blog.wired.com/cars/2009/01/tesla-motors-jo.html

Tweaking almost done

My latest settings in the Zilla seem to be working great for drives:
Battery Amp Limit: 500A
LBV: 67V
LBVI: 71V

I have the current I need for hills & short bursts of acceleration, and I am not in danger of going below the under-load 1.2V/cell limit (57.6V in the 96V pack) which would damage the batteries.

I'll be driving 20 miles a day (or less) while I break the pack in for the next 500 or so miles.