The Inhaler - All-Electric 23 Model T Autocross/Drag Truck

[toddshotrods]

Thanks 78.

[rwhite692]

Really cool project. What are the specs on that GE electric motor?

[toddshotrods]

Originally Posted by rwhite692

Really cool project. What are the specs on that GE electric motor?

Thanks.

It's an 11" (dia) motor from a Hyster forklift. Underwhelming stock specs are:

DC 36/48 volts
14.00 KW
RPM 1000
60 Min Duty Cycle
Class H Insulation
330 Amps

It's currently wound SepEx (separately excited armature and field), but I will be converting to series wound field coils. I'll probably swap in a set of refurbished field coils initially, but the plan is to custom wind a set for this application. It should turn 5-6K, and put out around 500hp/1000ft-lbs. The ultimate battery pack will be 330v/2070amps, and the motor will be built to make use of that. The controller is a new one coming out (currently in development) with 500v/2500amp max numbers. That battery pack is actually capable of supporting over 900hp, but I don't think my motor will be capable of that.

[strtcar]

Wow, really neat project. Keep the updates coming.

[toddshotrods]

Originally Posted by strtcar

Wow, really neat project. Keep the updates coming.

Thanks strtcar!

I've been working on plans and design stuff and I am really happy with how things are working out. I have countless hours in little details that will show up later in the build.

I figured out today that my plan to hide the roll cage in plain sight is working perfectly. I think I can get the rear down down tubes to pass inside the main body, meaning they won't be hanging out in mid-air going from the main hoop into the bed. From first glance, you'll be able to pick up clues that there is a full cage, and find more and more of it as you look deeper. The front bars will be exposed (running on either side of the motor), the rear down tubes will be visible inside the bed poking out of the body (when you get close enough to see in it), and a little of the front hoops running down behind the windshield posts will be seen. Just enough combined with the wheel/tire combo, and IFS, to let people know that there's something more sinister going on.

[MarkM66]

Cool project.

Maybe you already stated this, but what kind of batteries are you going to use? How many or what size will they be?

Any idea on milage range between charges?

[toddshotrods]

Originally Posted by MarkM66

Cool project.

Maybe you already stated this, but what kind of batteries are you going to use? How many or what size will they be?

Any idea on milage range between charges?

Thanks Mark.

Since I am so freakin longwinded , I underlined the answers to your questions, so you can skim through if you don't feel like reading yet another one of my novels.

Actually I didn't mention that - I meant to but forgot. I plan to use A123 (26650) cells. They're lithium-based, but I can't remember the exact compositition right now. They're the highest energy density of any currently available battery. They are what come in the larger DeWalt cordless tool battery packs. The downside is they're not commerically available. The company won't sell them to the general public. I have three options: Get an inside connection, get sponsorship, or buy 225 new DeWalt packs from a distributor and start dissecting (and recycling a lot of plastic).

They're little round cylindrical cells, about 1" diameter, and a tad over 2.5" long. I need 1800 of them! 18 strings of 100 series-wired cells, then paralleled. They're 3.3 volts each, so the 100 cells in series gives 330 volts for each string; then wiring those strings in parallel gives the 2070 amps. The other thing about these cells is they're the only ones that can be pushed as hard as they can, to deliver 2000 amps from such a small pack. I've done the math on all the others, and nothing comes close.

To hold them all together, I will be doing CAD/CNC cases that the cells drop into. The cases will fit under the seats, between the floor and belly pan, and between the frame rails and driveshaft tunnel, and kind of roll up behind the seats a little. I think it's going to work out to three cases on each side. That would make each case about 50-60lbs - easy to handle. The whole pack will weigh no more than 400lbs with cases, battery management system, etc. That's the key to the 1200lb final weight goal.

I should get 50-60 miles off a charge, driving conservatively, and maybe half that pushing hard. The funny thing is I would have been happy with ten, because I just wanted to be able to race. The additional range comes from A123 cells being so incredible. I think I'll have enough to do some short road courses. I'm seriously considering a little generator trailer (with a matching T bed) that would give me pretty much unlimited range. It would also be nice for recharging at the track.

[toddshotrods]

I've been working with the company that is developing the new motor controller, and had to revisit my own plans to make sure my truck's design isn't the weak link in the development chain. With the new battery chemistries available now (for a price) the day for serious electric-powered performance is just around the corner. The controller being developed will be capable of 1.6 MEGAWATTS of power!!! That's 2145 horsepower!!! Also, the torque of electric motors is usually substantially higher than the horsepower numbers, and available from 0 rpm!

I don't really anticipate making or using that much power, but my plans were for a relatively measly 500hp/1000ft-lbs. The main limiting factor was my 90" wheelbase, which was purposed to make it fun to drive on an autocross course, and extremely challenging in a straight line. If I tap even half the power that controller is capable of supporting, a 90-inch wheelbase becomes more of a liability than a challenge. I decided to stretch the wheelbase out to 108 inches, and use the current mild steel chassis as a development mule. I plan to eventually replace the whole chassis with a full round tube, chrome-moly, one that will be heat-treated after welding. That plan came from a discussion on this forum about roll cages.

I revisted my artwork to reflect the new changes and add more detail. It still has the 2x3" rectangular frame rails, that will really be replaced with round tubing. I didn't have to stretch the front-three-quarter view rendering because I had already taken artistic license with it, and stretched it out to make it look better. That should have been my first clue. I added some roll cage tubes, the forced-air cooling unit, a better representation of the grille, and the motor controller in the bed. There's also a 108" side-view, and full sketch of the rear-three-quarter view.

The stretch also provides room for more batteries - the cases will extend from under the seats, back, and under the bed. I didn't do those in the rendering or drawings yet. It goes from 1800 cells to 2992 of them. The output increases to 449 volts/2530 amps. The truck's weight will go up from 1200lbs to about 1500lbs. Range should increase to around 100 miles per charge.

[avewhtboy]

Really interesting idea you have going here, looking forward to seeing it
progress, will sure be unique in the road racing world.

[silver63c10]

This is an awesome project, man, should be an absolute blast to autocross. Looks like it will look pretty mean, too. Definitely can't wait to see more progress.

EVs have really gotten my interest lately, it's almost like hot rodding back in the 50's was with all the new tech and progress being made. I've been toying with an attempt at an electric bike, but haven't had the brainpower, or excess cash , to devote to even getting started on the research for it.