Toyota Truck Conversion

This conversion project will start with a 93 Toyota, short cab, 2-wheel drive pickup. This vehicle was chosen for the following reasons.

1. Small lightweight vehicle (2700 pounds)
2. Ability to carry a load (GVWR 4400 pounds or 1700 pound useful load)
3. Easy to work on (Front engine rear drive)
4. 1993 Truck is pretty simple (no power steering, no fancy computers to disconnect)
5. New enough to be able to buy parts, but old enough that used ones can be found for a reasonable price.

The major components used on this conversion will be as follows:

Netgain 9 inch motor
http://www.evsource.com/tls_warp9.php

Electro Automotive Motor adapter
http://www.electroauto.com/catalog/adaptors.shtml

Cafe Zilla Z1K-HV Controller
http://cafeelectric.com/shop/index.php?main_page=index&cPath=1

Monzanita PFC-30 Charger
http://www.evsource.com/tls_pfc30.php

Trojan T-125 Deep Cycle Battery
http://www.trojan-battery.com/Products/GolfCart.aspx

These are all high quality components that are proven reliable in many electric vehicle conversions. The Netgain motor is heavy duty and is built stronger than it needs to be. It will run cool under heavy loads and has a great reputation in the EV community.

Electro Automotive has been building motor adapters for years and the Taper Lock hub is very strong. This adapter keeps the Toyota clutch and flywheel for easy shifting and durability.

The Cafe Zilla controller is the absolute best controller that money can buy. It is also one of the few controllers around that will take voltages over 144 volts. This conversion is going to use 180 volts (30 batteries, 6-volts each). The maximum voltage on this controller is 300 volts. That spec might be useful if I ever upgrade to a Lithium battery pack.

The Monzanita Charger is voltage adjustable if the size of the battery pack is changed someday. The Charger will also work from 120 ac to 240 ac inputs. The Amperage draw is also adjustable, so that if you have to charge from a 15 amp outlet, this can be done without popping the breaker.

The Trojan batteries are some of the best lead acid batteries on the market today. They are warranted for 3 years with 1 year full replacement. They have only 2 downsides; one, you have to check the water level about once a month and, two, they are heavy at 66 pounds each.