Electric Ranger Conversion Project

The project, to take a standard Ford ranger and convert to electric vehicle for local use due to the high costs of fuel.
Having already built a electric bicycle and electric ATV, I thought it is time for this project.
I have chosen a 144 volt system with a Netgain Warp-9 motor, Curtis 1231c controller.

Saturday, June 28, 2008

Why a new donor is better..

I have removed all non essential items, spare tire and brackets, muffler, intake, some air conditioning parts. I have kept the truck running for now in order to move it in and out of the garage. I spent the better part of Saturday removing and replacing the spring mount, this turned out to be quite the pain due to rusty parts and murphys law fighting me at every turn. I will have to pick up new hardware to finish the task. Speaking of murphy's law.. the same side REAR mount was found to have too much rust so that will need replacement as well. Both cab perches in the rear are also rusted and new ones have been ordered as well. Note to self... next conversion, find a new or newer vehicle, a lot of labor here just for the glider and no real EV work done yet.
My motor has still not landed, getting impatient now.. ordered in May, hope to see it soon.

Thursday, June 19, 2008

Step 2: Getting the hands dirty


I had been driving the truck in to find any problems and discovered issues that will need to be corrected to make a dependable glider for conversion. I found that the air conditioning doesn't work well, so I have made the decision to not work it into the EV system.
The list seems to get longer at every turn, but that is going to be the case with a 15 year old vehicle. I discovered a water leak in the cab and removed the seats and floor coverings to clean up the floorboard, the source appears to be weather strip around the doors.
I have removed the bed box to access the frame and components that need to be removed.
During this I found that one leaf spring mount was rusted through and got a replacement from the dealer to replace it.
While I am waiting for my backordered Warp-9 to arrive, I will be removing the muffler, fuel tank and other gasoline engine components.
I have almost all the components except the batteries and motor, the steering box arrived yesterday.