| Config | Cells | V/Cell | Pack | Capacity | Total | Weight | 30 mph | 60 mph |
| AGM | 12 | 12v | 144v | 138 Ah | 19.9 kWh | 1200 lbs | 43.6 mi | 25.7 mi |
| GBS | 48 | 3.2v | 153.6v | 100 Ah | 15.3 kWh | 370 lbs | 48.5 mi | 29.0 mi |
| Tesla | 6 | 22.8v | 136.8v | 242 Ah | 31.5 kWh | 330 lbs | 96.7 mi | 56.0 mi |
Building a EV is great, but you must ensure you are legal otherwise this will all be a waste of time.
1. Insurance
Most companies will offer “liability only” insurance, i.e. everyone else is covered, you will not get anything for the car if it stolen/burnt/attacked by riotous mob/etc. Not good…
I currently have Geico covering my regular cars and they were very happy to offer for $200/6months increase to extend liability coverage to the electric bus.
The main alternative is “Classic” insurance, which known as “agreed value” – the problem here is most companies (I have another VW covered by Hagerty) will not insure you for daily driver (i.e. commuting) – this leaves you in limbo… The policy you need is called “stated value” here a local office or friend is what you need. I have friend at State Farm who sorted out a plan. I have to provide receipts for the conversion work and proof that the vehicle is street legal.
2. Tags
Initially I registered the vehicle with a standard tag. Following an inspection by GEFA which allows you claim the Georgia state tax credit for converted ZEV (zero emission vehicle) you need that inspection document to take to the tag office, with the original tag and AFV registration form.
The AFV tag allow you to use the HOV lanes with only 1 passenger, very useful for the airport run.
3. Tax Credits
a. Federal tax credit
IRS Form 8910 – 10% federal tax credit for converted vehicles (up to $4000)
b. Georgia state tax credit
I live in Georgia so there are some special codes just for this state, for 2009 the applicable code entry is: GA Code 48-7-40.16 Income tax credits for low-emission vehicles – an additional 10% state tax credit for converted vehicles (up to $2500)
This does require an inspection to prove the vehicle is zero emission and that it is capable of highway speeds.
c. Filing
The federal return does not require you submit anything more than the 8910 form which can be done through e-file. I used turbotax (which is aware of both the federal and Georgia tax credits).
However the Georgia state does require send in the paper certification which cannot be e-filed, so it mail in return.
StealthBus in the media:
http://www.gwinnettdailypost.com/localnews/headlines/Couple_plans_green_work_day_104542669.html
StealthBus on forums:
http://www.diyelectriccar.com/forums/showthread.php?p=138913
http://www.diyelectriccar.com/garage/cars/196
http://georgiadubs.forumotion.net/stockornaut-f21/the-stealth-bus-t2147.htm
Great EV links:
http://www.evalbum.com – photos and details of other projects for inspiration
http://www.diyelectriccar.com – very good forum for ~EVer’s, useful information and discussion, I am “chivey”
http://www.evconvert.com/tools/evcalc/ – extremely useful calculators to estimate your vehicle
Components / Datasheets / Manuals:
http://www.go-ev.com/WarP.html#WarP_9 – Warfield electric ~WarP 9 motor
http://www.evsource.com/datasheets/logisystems/users_manual.pdf – Logisystems user manual
http://www.cdpowercom.com/product/battery/vrla/pdf/mr12_490.pdf – C&D Technologies AGM battery
http://www.evsource.com/datasheets/braking_system/vacuum_kit.pdf – Vacuum brake kit
http://microcontrollershop.com/product_info.php?products_id=893&osCsid=cf78aef068dc74ad19a42afa585e5245 – PIC uP kit for prototype BMS
http://relays.tycoelectronics.com/datasheets/LEV200_ds_9-1773439-1.pdf – ~LEV200 contactor
http://www.datasheetdir.com/V23234-A1001-X036+Solid-State-Relays – “Bosch” relay used for all secondary circuits
http://www.westach.com – gauges for Amps and Volts
http://www.saveabattery.com – aux battery charger (100-240v input voltage)
Workshop:
http://www.stockornaut.com – VW restoration shop
EV suppliers:
http://www.grassrootsev.com – brought the Motor and Controller from here
http://www.evsource.com – brought the vacuum booster for the Brakes and some of the very large lugs from here
http://www.kta-ev.com – brought various components; circuit breaker, voltmeters, ammeter, shunt, second contactor and lugs
http://www.revoltevc.com – brought Charger, primary cables (6, 2/0 and 4/0) and boots from here
http://www.evolveelectrics.com – brought Lithium pack and BMS
evcomponents.com (now defunct) – brought replacement contactors
VW info:
http://www.ratwell.com – awesome site with great info
VW parts suppliers:
http://www.busdepot.com – ordered various interior parts, lens and brake components from here
http://www.bus-boys.com – ordered dash panel for gauges from here
http://www.socalautoparts.com – ordered replacement axles from here
http://www.mamotorworks.com – ordered sliding windows from here
Other resources:
http://www.cadsoftusa.com – schematic capture package
Web resources:
http://www.tiddlywiki.com – a very useful single page wiki engine used to build this site
http://tiddlythemes.com/#Blackicity – wiki theme used for this site + with my own (very) minor tweaks 🙂
Primer going on
Not all the bus was metal…
3D model of new RPi based head unit.
Stealthy got to top of hill and then shutdown⦠seems that at some point in the past the DC-DC inlet fuse blew and so for last few trips the aux battery has been slowly running out⦠it finally hit 9.5v and the main controller decided that was not quite enoughâ¦
Stealthy out from winter storage⦠run a bunch diagnostics on the pack⦠ending up removing 4 cells from the pack. Cells #40 and #48 were really not working right. Now running 44s1p configuration⦠adjusted soliton config accordingly. Need to adjust the BMS settings. Seems the GBS 100Ah cells just sag really badly. Canât see them actually achieving 3C discharge. Have enough trouble getting to 1C. Will try running them again for the summer and see what happensâ¦
Cell #48, cleaned, crimped a new lug on the cable, liberally coated in NOOXID…. end result Voltage sag+Thermal rise… same as before – Bugger!
New Toy…
