Enterprising local family uses their EV to achieve net-zero in their Durango residence.Read More
Enterprising local family uses their EV to achieve net-zero in their Durango residence.Read More
Mancos is a small town with a diverse populace, part tourism hub – gateway to Mesa Verde NP – part art colony, and part ranching community. The town’s premier annual social event is Mancos Days, which will feature a main street parade on the 30th of July, followed by a car show at Boyle Park (https://www.mancosdays.com/). EV owners are being encouraged to bring their EVs to join in the fun, by none other than David McNeil, Colorado’s pre-eminent EV activist (normally ensconced in Denver) returning to his hometown (Mancos HS class of 1962!) for the event. If you might be interested, contact David at email@example.com, so he can organize EV participation.
Buying a used EV raises questions about the condition of the battery; a new startup is addressing this need with big data.Read More
EV sales in 2021 soared worldwide. The legacy manufacturers are struggling to catch up.Read More
We’ve gotten out of the habit of posting the Denver Electric Vehicle Council (DEVC) monthly newsletter. We want to get back in it! You’ll find the pdf below.
There are a couple of interesting articles in this month’s DEVC issue on batteries – new advances in energy density, an update on battery recycling, and a new EV (Lucid Air) which touts a battery with higher energy density than Tesla’s (reprinted from ev4corners!)
For a comprehensive overview of why battery recycling and technology improvements are so important, see David Roberts’ (Volts) story on problems related to minerals needed for the clean-energy transition. You don’t have to be a scientist or economist to understand the information provided in this article. Mr. Roberts does a really good job of breaking it down for those not as technically minded, as well as giving plenty of concise information of interest to those who are.
The DEVC newsletter also includes some articles on changes to the schedule in retiring some of the San Juan Generating Station’s coal-fired generation units, which are relevant to us in the Four Corners area (San Juan Generating Station is located not too far west of Farmington, NM.)
Enjoy the newsletter! Better yet, go to www.devc.info and sign up to receive it yourself. DEVC is the Colorado affiliate of the national Electric Vehicle Association. They are one of the oldest national electric vehicle volunteer organizations. “The Electric Vehicle Association educates and advocates for the rapid adoption of electric vehicles.” To join them, and DEVC, to https://www.myeva.org to become a member. When you sign up, you can choose DEVC as your affiliated chapter.
EVs are often designed by the same thinking that turned carriages into “horseless carriages” without fully incorporating the advantages of automobiles. What EV advantages can be improved by redesigning the automobile? Send us your ideas for our design contest.Read More
With its new entry in the BEV high performance sedan, Lucid has revealed exciting new efficiencies to make 520 miles without a charge, and add 300 miles of range in just 20 minutes.Read More
Part 1 discussed what is required to use the home backup feature sold as an option for the upcoming Ford F-150 Lightning pickup truck. While researching that article, I spoke with Dominic May, the Energy Resource Program Architect at the rural electric cooperative (co-op) serving my community in the southwest corner of Colorado, La Plata Electric Association (LPEA).
His answer to the F-150 Lightning question was pretty simple; you can read about it in Part 1 of this post. What was more interesting were the incentives LPEA may make available for all their EV-owning customers. LPEA is now gaining experience with their first-in-the-state electric school bus as a Vehicle to Grid (V2G) source of peak-hour energy. Now they’re turning their attention to possible V2G incentives for all their EV-owning customers.
That’s the dream of V2G, that we can multi-purpose this big fleet of batteries out there in our service area.Dominic May, the Energy Resource Program Architect
V2G uses a specific kind of charger, a bi-directional charger. It allows the grid to fill your car’s battery with electricity. It also allows, at pre-set times of the day, the grid to pull electricity out of your car’s battery. Under a V2G program, the electric company doesn’t just provide electricity to you. You also provide electricity back to them at the specific times when it saves them the most money: during peak energy use hours of the day.
In southwest Colorado, the Tri-State Generation and Transmission Association owns and maintains the large power plants and transmission lines that bring electricity to all the area electric co-ops. Tri-State charges LPEA a monthly demand charge of $20 per kW of peak demand. That means every month, Tri-State looks at the one hour of highest demand from the LPEA service area and charges $20 for all the kilowatt hours delivered during that hour. If LPEA as a whole uses 100,000 kW during its highest hour in a month, Tri-State charges them $2,000,000 for that month’s demand charge. That is addition to the price LPEA pays at lesser rates for electricity supplied during all the non-peak hours.
LPEA is a winter peaking, evening peaking utility. It’s pretty much never fully dark until 5 PM, even in the depth of winter. Our peaks usually happen between 6 and 7 PM. It’s about an hour after dark, everything’s gotten quite cold and all the heat is coming on, everybody’s home, dinner starts getting cooked, et cetera. All the devices in the house come on.Dominic May, the Energy Resource Program Architect
If your 80 kWh battery EV rolls into the garage at 5:30 PM with 60 kWh left in the battery and plugs into a V2G charger, it could supply 40 kW to the grid between 6 and 7 PM to allow having 20 kWh left in the battery in case of a night emergency. (Most EVs on the road today could get 60 – 80 miles on 20 kWh.)
The EV could then easily regain the 40 kW it sent out by more slowly pulling it in overnight, when electricity rates are lowest. While you ate dinner, relaxed at home and then slept, you helped save your electricity provider 40 kWh x $20/hr = $800. Since electric co-op members include all your neighbors and everyone in their service area, you’ve helped everyone in your community save money. Your electric co-op or company will want to find a way to make that worth your while.
LPEA recognizes people participating in a future V2G program would need to expend some money to be able to take part. Bi-directional chargers are significantly more expensive than your basic Level 2 home charger. EVs are still more expensive than comparable petroleum-fueled cars.
LPEA is working on creating a battery storage program for customers with home back-up batteries, like Tesla Powerwalls or LG batteries. We hope to learn from that and extend the same incentives to customers who want to participate in a V2G program. The V2G program will need to include an aspect controlling the time the customer is willing to participate, and how much of their battery capacity they are willing to contribute each day.
We want to pass as much of that back to the customer as we can. We’re considering upfront rebates for V2G equipment purchased and annual credits based on energy sent back to the grid, things like that.
Right now, we have the small demand charge of $1.50 per kW we pass through to non-time-of-use rate members, but that’s obviously not reflective of the $20 the whole membership pays. Equity is a big consideration for LPEA. We will need to balance the price signals we offer to the V2G participating members so we don’t punish lower- and fixed-income members with electrified homes.Dominic May, the Energy Resource Program Architect
If you live in LPEA’s service area, keep an eye out for upcoming battery storage programs offerings. If not, contact your local electricity provider and ask them if they have any plans to implement a home battery storage or Vehicle-to-Grid incentive program in their service area. Let them know you’d be interested in participating.
People served by rural electrical co-ops can have a strong influence on the board members of those organizations. Encouraging them to look into these types of programs may be just the push they need. Investor-owned utilities also might be influenced by their customer’s interest in taking part in V2G programs. If you are served by an investor-owned utility, such as Xcel Energy (CO), PNM (NM) or Rocky Mountain Power (UT), check their website or give them a call to find out what their plans are. The Navajo Tribal Utility Authority (NTUA) is unique as the largest multi-utility enterprise owned and operated by an American Indian tribe. If you live in their service area, give them a call to find out if they are investigating how they can use distributed battery storage resources to bolster their electricity distribution system.
Finally, here’s a nice short video to sum up V2G from Nuvve.
Word on the internet has it that Ford will open their ordering process for the F-150 Lightning this Thursday, January 6, 2022. It seems a good time to do a deeper dive on Ford’s home backup power option available for their much-awaited electric pickup truck.
This is Part 1 of a two-part post. Part 1 discusses the specifics how much this option will cost, how it will work, and can it live up to Ford’s promises.
Part 2 will discuss other things you can do with a big electric truck’s battery, to both help your community and save some money for yourself. It’s called Vehicle-to-Grid (V2G) and it could be coming to your neighborhood sooner than you think.
Here’s the home backup promise on Ford’s website:
In Part 1, each part of this promise will be discussed. In Part 2, we’ll learn how one SW Colorado rural electrical co-op plans to work with customers wanting to use the back-up power feature to provide benefits not just to EV owners, but to all co-op customers.
The backup power option is not available for all F-150 Lightning models. In particular, it will not be available on their lowest priced PRO model, which has a base price of $40,000. To take advantage of the backup power option, you must purchase an extended range battery model, the lowest cost of which appears to be the $74,000 XLT.
Ford’s website indicates the 80-amp Ford Charge Station Pro comes standard with extended range battery models. The Charge Station Pro is an extra piece of equipment which will allow your F-150 Lightning to both draw electricity FROM the power lines feeding your house to fill up the truck’s battery AND allow it SEND electricity INTO your house when those power lines are down. It is what’s known as a bi-directional charger. It allows peak charging power of 19.2 kW, much higher than the typical 7 kW a home Level 2 charger provides.
The 32-amp mobile charger which comes with all the F-150 Lightning models will also be included. This charger sends electricity in just one direction: from a power outlet to the truck’s battery. The charger is delivered, coiled neatly in a canvas travel case, as an electrical cord with a charge plug on one end. At the other end there is a choice of two adapters, one you can use to plug into a regular 120V outlet and another you can plug into a 240V outlet.
You can use the 32-amp charger wherever there is an outlet, from a regular 120V outlet on a friend’s porch to an electrical hook-up at an RV campground, which delivers as much power as a Level 2 charger.
Carrying this mobile charger in the truck with you could come in handy if you wind up stuck on any road that has closed due to winter storm conditions (as recently happened in Virginia) or an accident. If you can get off the highway, you could plug into any wall outlet (120 V) and heat your vehicle without running down the battery until traffic was able to move again. If you have an F-150 and a full battery, other EVs could plug into your truck’s 120V outlets to run their heaters until traffic gets moving again.
To use the home backup feature, you will need to get a professional electrician to install the 80-amp Ford Charge Station Pro and an automatic transfer switch at your house. The transfer switch automatically disconnects your home from the grid when the power goes down. That is necessary so your F-150 does not feed battery power back out on the power lines at your house during a power outage, which could cause a severe hazard to power company workers working on the lines.
You will need an 80-amp circuit installed to serve the Charge Station Pro. This won’t be a problem for most homes, but some with older electrical systems may need to upgrade their service with their electric company to carry that many amps.
In May 2021, Ford announced they had partnered with a company called Sunrun to:
facilitate the installation of Ford’s charging stations and energy integration system for residential customers.https://www.pv-tech.org/ford-selects-sunrun-as-installation-partner-to-make-new-f-150-lightning-backup-power-source/
At Sunrun’s website, they list all of the Four Corners states except Utah as states where they operate. I am not aware if Sunrun currently operates in the Four Corners area. Before your F-150 Lightning order goes to production, you’ll want to confirm what company, Sunrun or a solar contractor local to you, would be able to work with you to install the 80-amp Charge Station Pro and install a new, or modify an existing, home solar system.
No. It is basically the same as if you were adding a new electric appliance to your home. You usually don’t have to notify your electric company to do that. However, the electrician who does the installation work at your house will check to be sure your current electrical panel and service can handle the amount of power the F-150 Lightning would both pull from and push into your home’s wiring. They will let you know if any upgrades need to be made, and if so, how much they will cost.
Yes. Ford recently announced the F-150 Lightning extended range battery will have a capacity of 131 kilowatt hours. For comparison, a typical Tesla home battery used for home backup power holds about 13.5 kWh. However, remember any energy your home uses out of the truck’s battery will decrease the number of miles the truck will be able to drive before getting re-charged.
If your home has solar, you may be able to modify your electric service so the solar array could send charge into the F-150 Lightning’s battery during a power outage, along with powering your other household electric needs. Your solar array would need to be sized to provide enough power to cover both your home’s needs and have power to spare to supply the truck with extra energy to allow you to drive it around during the blackout, if needed.
Ford received more than 200,000 reservations for the Lightning, which were made at a cost of $100 each. Starting in January 2022, they will begin sending invitations to the reservation holders to order at staggered times. If the system works as it did for the Mustang Mach e, it will cost $1,000 to place an order. Once the order is placed, it will likely take 6 months to a year before you actually get the truck. According to communication sent recently by Ford to reservation holders:
Now, this kind of demand means many of you won’t get a 2022 F‑150 Lightning™ truck, but rest assured we will hold your reservation so you’ll have a chance to order a future model year.Ford communication to F-150 Lightning reservation holders
Stay tuned for Part 2 of this post. I plan to get it published in a week or two.
Part 2 will discuss other things you can do with a big electric truck’s battery, to both help your community and save some money for yourself. It’s called Vehicle to Grid and it could be coming to your neighborhood sooner than you think.
Durango, Colorado’s 9-R school district will soon be the owner of a brand-new, all-electric Bluebird bus. Thanks to a grant from the Regional Air Quality Council’s ALT Fuels Colorado program and southwest Colorado’s La Plata Electric Association (LPEA), the school district is getting the bus entirely for free. This was made possible by the state grant funding, which covered much of the $210,000 difference between the cost of a diesel vs electric bus, but also by LPEA’s initiative in penciling out how both they and the school district could benefit from nascent vehicle-to-grid (V2G) technology.
It will be the first use of V2G technology with a school bus in the state of Colorado. LPEA aims to demonstrate how electric school buses can provide benefits and savings to everyone in their service area. I spoke with Dominic May, LPEA’s Energy Resource Program Architect, to learn more about the bus, V2G and the benefits.
LPEA contributed about $150,000 to cover the remainder of the cost of the bus and to install a 60 kW bidirectional charger at the school district’s bus barn. Bidirectional chargers are at the heart of V2G technology. They take the AC power provided by LPEA’s electrical grid and turn it into DC power which fills the bus battery. They can also go the other way and change the DC power in the bus battery into AC power, which can then be sent back into LPEA’s electric grid.
The bus and the bidirectional charger are now owned by the school district, but they have an operational agreement with LPEA which allows LPEA control of the battery for the coop’s benefit.
V2G is the big reason I got interested, in addition to finding a project that could be entirely free for the school.Dominic May, Energy Resource Program Architect
We have an operational agreement that we will run the battery to perform energy arbitrage in the background. The school district will never notice we’re doing it but will always charge at our cheapest off peak rate.Dominic May, LPEA Energy Resource Program Architect
The bus battery holds about 175 kWh of energy. It will charge overnight and during mid-day when the bus is back at the bus barn. On the commercial time-of-use rate LPEA provides, these are the cheapest times of day to use electricity.
After it returns from its morning route at about 9 AM, the bus will need about 3 hours to refill the battery. It arrives back from its afternoon route at 4:30 or 5:00 PM. LPEA’s evening peaks usually occur at about 6:30 or 7:00 PM. They will recharge the battery up until the evening energy use peak starts ramping up. As the peak 15-minute period approaches, LPEA will signal the bus battery to push 60 kW onto the grid. (60 kW is the maximum rate the bidirectional charger can discharge at.) When the peak is passed and peak rate time is over, the bus will continue recharging into the night.
LPEA’s supplier, Tri-State Generation and Transmission Association, charges LPEA a monthly demand charge based on their peak monthly usage. For every kilowatt LPEA uses during their peak 15 minutes in each month, Tri-State charges $20/kW. By reducing their peak with the bus battery, LPEA realizes 60 kW x $20/kW = $1,200 savings a month. Says May, 60 kW of demand “that’s like a dozen houses or more coming off the grid during the peak hour.”
Just selling that off-peak energy, we don’t make much more than $0.02 per kWh and it would’ve been close to a 400 year payback period, but doing demand managing with the V2G system turns it into about a five to eight year payback period.Dominic May, LPEA Energy Resource Program Architect
After that, the savings will accrue to LPEA’s membership.
The electric fuel for the bus will be one sixth the cost of diesel. The electric motor and drive train require much less maintenance than gas or diesel buses. No oil or coolant changes, no air filters, no tune-ups. LPEA’s use of the battery doesn’t require any changes to the regular schedule the bus would run. They only use it when it would be sitting at the bus barn anyway.
A diesel bus will have to be sacrificed as a condition of the state grant dollars. The school district’s oldest bus must have its axles broken or its engine cored to ensure it is permanently disabled. The intent of the state grant is to reduce air pollution by taking old diesels, which have very dirty exhaust, off the road.
Any school or other buildings designated as emergency shelters would need to be outfitted with a bidirectional charger, and the electrical infrastructure to support it, to be able to receive the energy in the event of a blackout. Once installed, these chargers could also be used as fast chargers for any electric vehicle in non-emergency circumstances.
They definitely can serve as an emergency generator. One of the cooler things they could do is come up and power something like a FEMA shelter. However, the caveat is the places have to be wired up to receive this and infrastructure will need to be built to support it.Dominic May, LPEA Energy Resource Program Architect
Demand management is getting bigger and bigger, especially as renewables come on the grid. You have this extremely cheap and clean energy, but it’s intermittent. So, anything you can do for storage is really what this is all about. That’s the dream of V2G – that we would multi-purpose this giant fleet of batteries that are out there to make the grid cheaper, cleaner, and more resilient.Dominic May, LPEA Energy Resource Program Architect
On some grids, the power used at peak times is dirtier than at other times. For example, on a grid which has solar generation, and uses natural gas “peaker” plants to provide energy during the peak evening hours just as solar is waning, energy used at peak times will have higher carbon dioxide emissions per kilowatt. By decreasing the amount of kW used at peak times, those higher emissions are avoided.
On our current fuel mix, the school bus will reduce carbon emissions by about 2 ½ times its weight in carbon dioxide every year.”Dominic May, LPEA Energy Resource Program Architect
When greenhouse gas emissions are decreased, the other pollutants associated with burning petroleum are also decreased. Diesel engines emit particulate matter, nitrogen oxides, carbon monoxide and numerous toxic volatile organic compounds.
The bus is expected to arrive in Durango by the end of October 2021. It’s now at its final stop, getting outfitted by a company on the front range to the school district’s specifications.
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The climate costs of hydrogen generation are coming into focus, and the picture is not pretty.Read More
1) Tesla sales soared globally and nationally, jump-starting the EV revolution and attracting big investments in EV companies. Tesla dominates the global market for BEVs; no other manufacturer has even a fifth of the global sales of Tesla. At one point Tesla’s model 3 sales in California made it the single most popular new vehicle model bar none. As Tesla stock soared in price (at one point giving Tesla a market valuation greater than that of all the legacy car manufacturers combined), investors sought out other firms in which to plunk their money. Rivian raised several billion in new funds. Other investors were not so lucky. Nicola apparently fudged the numbers and collapsed after the Securities and Exchange Commission went after them. Lordstown fibbed when they said they were ready to begin sales, and its stock also collapsed, in part because Ford announced that Ford was to market to exactly the same niche market (electrical utility fleets) that Lordstown had bet its future on.
2) The major legacy car manufacturers got into a publicity arms race over promises about the future of EVs, but didn’t actually produce many. Most announced they were going to spend X dollars pursuing electrification, and that they planned to have Y percentage of their sales electric by date Z (or cease selling regular vehicles ICEs (Internal Combustion Engines) by a certain date. Given their inability to meet any of the previously announced EV sales deadlines, one has reason to be skeptical, but the fact that they feel compelled to (over?) promise may be better than inaction.
3) VW may be an exception, as they committed billions of their own money to ramping up charging infrastructure. Whereas VW was legally obligated to spend the fines leveled as a result of the diesel cheating scandal to construct the Electrify America EV charging network (by the end of 2021: 800 sites in the US, featuring 3500 chargers), VW recently committed to spending about $2B of their own unrestricted funds to more than double the size of the Electrify America charging network. To put their claims in context, the US presently has about 41K charging sites and 100K public chargers. By 2025 Electrify America intends to have 1700 sites and 9500 chargers. Electrify Canada will be similarly expanded, and VW expects to spend $86B by 2025 to pursue electrification. This one-upped GM, which had only promised $35B for the same time period. So there!
4) Tesla announced a vague plan to someday share its charging infrastructure with others, which will double the infrastructure for non-Tesla EV drivers. The financial details remain to be worked out. Presumably the fillup cost to non-Teslas will be higher than those to Tesla owners, though the costs might alternately be borne by the other car manufacturers (as being discussed in Europe). Regardless, when you find yourself somewhere with a nearly drained battery and a handy Tesla supercharger, the cost differential might be immaterial. How this would work physically (who needs to buy which conversion cables) remain to be determined. With the rapidly dwindling number of CHAdeMo connector users, this portends a glorious future in which the connectors become uniform and interchangeable. However, some car manufacturers (e.g., Porsche) are pushing for a doubling of the fast-charging voltage standard (from 480 VDC to 960 VDC), which might complicate things and raise the cost of building fast-chargers.
5) Biden targeted EV infrastructure for a massive buildup, but so far the Republicans have stymied it; the White House has plans for covering some of the blocked buildup using budget legislation. Political inertia is with the Democrats, but political power on the Hill is very close to gridlock. Stay tuned.
6) EV sales have spread out from sedans to SUVs and crossovers. There are now many all-wheel drive vehicles (AWDs) at mid- or higher price points, though availability is somewhat limited in some places. Among the car models with at least an AWD option are (ordered by base MSRP from low to high) (see link for pickup trucks):
Tesla Model 3
Tesla Model Y
Polestar (Volvo) 2
Tesla Model S
Tesla Model X
7) EV pickup trucks were supposed to emerge in 2020, but did not. First at bat is Rivian, but for the last year this new manufacturer has been promising deliveries in about “a month or so.” Ford and Tesla are teasing mass-market EV pickups, but no firm sale dates have been announced; Ford will sell them to electric power company fleets in 2022. GM is teasing a $117K Hummer EV: that’s a little rich for me, but the day of capable AWD electric pickups is nigh. I expect to see one locally in September.
8) Policy makers have woken up to the cost and complexity of rapidly expanding clean power generation and delivery of electrons for EVs, but no coordinated response is evident. For most, the major expenses have been penciled in for “later”. Texas ran into catastrophic grid failures during a winter cold snap, in part due to their inability to obtain power from neighboring states, which had power (Texas is the only continental state with a stand-alone grid). Texas legislators are now patting themselves on the back for bold new initiatives long adopted by other states (e.g., requiring the utilities to cold-harden their generators), but connecting the Texas grid to the rest of the nation is not on the table.
9) Climate-related natural disasters make the front page almost daily, but most media outlets cry for money to build structural defenses, not prevent climate change. Record-breaking temperatures, unprecedented wildfires, smoke plumes reaching almost all of North America, chronic coastal floods, record-setting deluges around the world, and agriculturally debilitating droughts would seem to be enough to get the worlds’ attention, but media coverage has focused only on mopping up the mess.
10) The city of Durango and La Plata Electric Association (LPEA) wrote a seminal EV readiness plan, but near-term changes are underwhelming. For example, in the “lead by example” element, LPEA committed to buying two Ford EV pickups when they become available sometime in 2022 (or 2023). Meanwhile, fast charging (DC) has finally reached the local area, with Pagosa (2020), Durango (July 2021), and Purgatory ski area (late 2021) acquiring moderately fast-charging capability. Those chargers should boost visitation by tourists and provide solace to local EV owners who might suddenly need to go a long distance. The EV readiness plan has put all the right processes in place; the heavy lifting – you guessed it – comes later. Stay tuned.
Join southwest Colorado’s La Plata Electric Association on Tuesday, July 27th at 6 p.m. for the second webinar in LPEA’s Beneficial Electrification series focused on electric vehicles (EVs).
Advanced registration is required: https://us02web.zoom.us/webinar/register/WN_YAx0dfXfTj2JXR4Rr_4ZmA
No joke. The 1971 VW Fastback pictured above is powered by a 2015 Nissan Leaf powertrain.
The powertrain of any vehicle includes the mechanisms which transmit engine power to a vehicle’s axles, and the axles spin the wheels. In petroleum-powered car, it includes the engine, transmission and axles. In an EV, power flows from the battery directly to an electric motor on the axle which spins the wheels.Definition of powertrain
Many of us have loved and lusted after certain classic vehicles from years gone by. For Mick Longley of Durango’s Busaru, those vehicles have been Volkswagens.
Recognizing the huge impact burning fossil fuels has on our planet’s climate, some of us regret we can no longer drive those cars or trucks. Or we’ve driven an electric vehicle and experienced how vastly superior they are and don’t want to go back to the cost and inconvenience of petrol power. For Mick Longley, this was a problem he could solve.
Mick’s love for classic VW’s started in the mid 2000’s when he picked up a VW Westfalia camper to travel around in. He moved out to Durango, Colorado in that van and started BUSARU, the VW to Subaru engine swap business. He had been holding onto the 1971 VW Fastback for a few years – awaiting a project.
I was initially going to put a Subaru engine into it but got re-inspired by the EV conversion scene. I had converted a 70’s Kawasaki motorcycle and a slough of classic bicycles back in the day, even had a small business doing that in CA called zombiEVintage.Mick Longley
For a deeper dive into Mick’s work on the Fastback, check out his YouTube channel video below and continue reading below the video!
As Mick expected, the mounting of the battery and motor were the most challenging parts. Most VW conversions rely on using the VW transaxle and adapter plate to mount an aftermarket motor, and batteries mounted in the cargo areas.
Since I wanted to use a mass-produced donor vehicle to keep costs low and reliability high, it brought up some unforeseen challenges. In a way, the VW chassis made the battery location decision for me. The floor pan was rotten with rust, which needed to be replaced anyway, so I just cut all of it out and built a frame out of rectangular tubing. This allowed me to keep the LEAF battery completely intact, including all of its safety mechanisms, as well as providing a structural component for the car – the many benefits of keeping the center of gravity low in the chassis! Once the battery was mounted it took a few days of playing with different drive unit mounting schemes. In short, once the battery was figured out, everything else came together pretty easily.Mick Longley
What was the biggest challenge in starting this project? It was believing it could be done!
Parsing the overall project into smaller projects really helps. Removing the internal combustion engine (ICE) equipment is actually a ton of fun. You get to see how cars are put together without the pressure or fear of breaking something you’ll need. In the case of the Fastback project, I knew I wasn’t going to be using any of the VW ICE equipment, including the transmission, so it was pure fun removing the old rusty grease-caked parts to make way for a clean EV drive unit.Mick Longley
In a Subaru engine conversion, the most intimidating part of the project for do-it-yourself DIY folks is the electronics. I have completed nearly 1000 electronics packages for the DIY Subaru-VW community and that experience really helped me navigate the electronics and wiring diagrams for the LEAF-based conversion. With the electronics mystery figured out, the conversion became more and more fun to work on, and a great learning experience. The next conversion will benefit greatly from what I learned on this one.”MIck
Does Mick plan to do more EV retrofits?
I want to get a couple more personal EV conversions finished before taking on customer work. These include a 1973 VW Bus (LEAF conversion) a 1965 GMC pickup (Tesla conversion), and a 70’s vintage Ford Bronco project that I’m converting for a friend.Mick
I am definitely interested in taking on projects once I get a little more experience converting my own vehicles. I like to experiment on my own vehicles first! I love to hear about other people’s EV projects though, so let me know what dreams you’re cooking up.Mick
Does he have plans to make EV retrofits of classic cars part of his regular business?
Yes, like with BUSARU, I plan for Regen EV’s to offer kits for DIY tinkerers to more easily retrofit their VW Bus and Vanagons (and possibly other vehicles) to electric power. I’ll keep supporting the VW community (especially the camper van VW’s) because they really represent the spirit of adventure and travel, and there’s nothing like cruising to an adventure destination on battery power!Mick
Rivian plans a very ambitious addition to North America’s charging network.Read More
By Guinn Unger
In January of 2020 I received information from Ford that I could order a Mustang Mach-E. I just needed to put down a fully refundable deposit of $500. So I did. I had been waiting for an all-electric SUV of at least medium size, and having something with at least a little bit of Mustang heritage looked good! (I have owned several Mustangs in the past.)
In July of 2020 I was asked to put down an additional $500 to confirm my order. (I actually gave the local dealership $1000 and Ford refunded my original $500 deposit.)
I ordered the Mach-E with all-wheel-drive which is important since I live in a part of SW Colorado where we get a good amount of snow each year. I also ordered the standard range battery since it was not my intention to take road trips in the Mach-E. It would be used mostly for local driving. And of course, I ordered the Rapid Red color!
I have to say it was not easy to get information about the car directly from Ford or my local dealership. They could have done a much better job of having contacts that knew something!
I was finally told the car would be built the week of December 14, 2020, but they did not give any indication of when I might actually receive it. It showed up at the dealership on February 6, 2021, and my experience with the dealership during the actual sale (strangely enough) was actually quite good. Durango Motors gave me a fair trade-in, and we closed the deal.
Overall, I am very excited about my Mach-E and I am really glad I bought it.
We bought our 2018 Chevy Bolt in 2018, feeling assured the 238-mile range advertised for the vehicle would meet our daily needs and make our most common weekend trips. Knowing Electrify America was making steady progress on installing DC fast chargers on interstates from coast-to-coast, we figured the Bolt would also allow cross-country trips on the rarer occasions we needed to make them.
Therefore, our decision to buy the car was based on two things: the size of the battery and how the battery management system (BMS) functioned.
On November 13, 2020, six weeks after we returned from our 3,200 mile round-trip road trip from Durango, CO to the top of Michigan’s mitten, Chevy recalled our Bolt due to concerns about the battery catching fire.
Chevy recalled a “select number” of 2017-2019 Chevy Bolts built with:
“high voltage batteries produced at LG Chem’s Ochang, Korea facility that may pose a risk of fire when charged to full or very close to full, capacity. As an interim remedy, dealers will reprogram the hybrid propulsion control module 2 (HPCM2) to limit full charge to 90%.”https://my.chevrolet.com/how-to-support/safety/boltevrecall
We had DC fast charged four or five times a day for each of the 3 days of the trip both coming and going. At several of those charging stops, we’d had to charge to greater than 90% so we could get to the next DC fast charger with some cushion.
No one wants to consider being trapped in their car, trying to slow down from highway speeds so you can bail out because your car is on fire. (Know that fires are far more likely in petrol-powered cars than EVs.) If we’d had to stop more frequently, what was already a really long trip due to charging stops would’ve been even longer.
Chevy’s interim fix is a BMS modification. We got the car reprogrammed right away, and as of 3/2/21, we’re still waiting to hear what the final fix will be.
A recall is issued when a manufacturer or NHTSA determines that a vehicle, equipment, car seat, or tire creates an unreasonable safety risk or fails to meet minimum safety standards.https://www.nhtsa.gov/recalls
The cause for the fire hazard in the Chevy Bolt is not yet settled. The Hyundai Kona Electric and Ioniq Electric are also on recall for battery fires right now, with batteries also manufactured by LG Energy Solutions, though at a Chinese facility.
On 2/24/21, LG stepped into the fray. In a statement on the Kona EV recall, LG states the Korean agency responsible for confirming the cause of the fires has not been able to confirm the problem is misalignment of the anode tab. They claim Hyundai misapplied the BMS fast charging logic proposed by LG. They are cooperating with the “relevant authorities” to discover if that had any connection to the fires. LG also says damage to the batteries’ cell separators has been confirmed as unrelated to the fires by a joint investigation team.
Hyundai has had more fires in their affected vehicles and their recall covers a larger number of vehicles. Rumors are circulating that for Hyundai, all battery packs may need to be replaced. Kona Electric owners are suing for depreciation the issue has caused. Chevy owners haven’t organized on that front yet, but I would not try to sell or trade in our Bolt until this issue is resolved. I think most buyers would hesitate to buy a Bolt affected by this recall.
I called the Chevy EV concierge on 2/27/21 after reading the following on Chevy’s Bolt Recall webpage:
A team of GM engineers has made substantial progress in identifying the root cause and potential remedies for this issue. They are in the process of validating state-of-the-art software that can diagnose potential issues early and restore 100% charge capability. A final remedy for this recall is anticipated for April 2021. Until that time, if you have not already done so, we recommend scheduling a service appointment with your dealership to update the vehicle’s battery software to automatically limit the maximum state of charge to 90 percent.https://my.chevrolet.com/how-to-support/safety/boltevrecall
I asked the concierge how a software fix (a BMS fix) would solve the problem. Would it detect changes within the battery and provide a warning to the owner if changes occurred which might lead to a fire? Then the battery could be repaired or replaced before a fire could happen?
The concierge said it has not yet been determined the final fix will be software. He said it hadn’t gotten to the point of even discussing if a warning system would used or required. They don’t yet know if it will be a software fix or a battery replacement. We might find out earlier what the fix will be, but the fix won’t actually be available until April 2021.
It seems GM appreciates the importance of maintaining the range promised to buyers at the time the vehicle was purchased. A ten percent range reduction may not sound like much to a judge behind a bench, but when you’re sitting in the dark, gravel parking lot in front of the I-70 diner in Flager, CO at 11 PM, hanging in there for yet another 20 minutes to be sure you make it to your motel in Colorado Springs two hours away, it seems like an awful lot indeed. GM would do well to keep their EV early adopters in mind as they plan for their all electric future. I hope they won’t leave us furious with the cure to this recall, whether it be for the battery or the BMS.
For good, in-depth reporting on this issue, check in at InsideEVs.com where reporter Gustavo Henrique Ruffo has been following the issue closely.
The Aptera will thrill efficiency seekers, and charge whenever it is parked in the sunRead More
Upcoming lecture will provide background for pending hearings on EV policy in Durango, ColoradoRead More
They don’t, but neither does your internal combustion engine (ICE) car, and no one whines about their ICE car in the winter (if it starts). All vehicles lose some efficiency when they are cold, but alert reader Richard Grossman pointed out a recent article (link: https://insideclimatenews.org/news/11022021/inside-clean-energy-norway-electric-vehicles/) on Norway’s adoption of EVs: 56% of new car sales, compared to 2% in the United States. This fact was highlighted in a recent Superbowl ad for Chevrolet, but remember this: the top FIVE countries for EVs sales are all near the Arctic Circle:
The linked article explores the reasons for Norway’s rapid adoption of EVs, which include celebrity endorsements, an early and rapid government-funded build-out of charging stations, and tax breaks that provide purchase price parity between regular cars and EVs. If you are interested in EV policy incentives, be sure to check out the lively article by Dan Gearino in the link above.
Opportunities for Durango-area readers to comment on EV policy in their area, plus new chargersRead More
EV adoption will be accelerated by the ready availability of “supplementary” high performance or long-range vehiclesRead More
Cost of EV ownership have reached parity with conventional vehicles over the life of the vehicle, says article in New York TimesRead More
EVs are 500% less likely to catch fire than conventional vehiclesRead More
They found an average of 2.3%/year range loss for the EVs on the road today. “If the observed degradation rates are maintained, the vast majority of batteries will outlast the usable life of the vehicle.”Read More
There are a bunch of fun stories in this one!