The Life of Riley

Mike

Dear Friends of Olive, as you know if you read the last post , we are planning to build an electric car in honor of a great lady.

For those of you dropping in the first time , do dig back into this blog and discover what a wonderful person was Olive Riley

Just two months ago she left us forever at the age of 108, loving life almost to the end. .

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First the good news. The Express Advocate, our local paper here on the Central Coast, is covering the story.

I’d suggested to their journalist, Terry Collins, that it would be interesting for the paper to follow the project.

Follow us from these first steps right until the car called, the Sirion Olive, is on the road.

Terri was enthusiastic and here’s the first article. There’s myself in green and Nathan Bolton, in red,
peering into the engine of the host car.

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We had high hopes for that article and it did not disappoint.

We need a host garage where not only the work can be done, but the public can come and have a look if they so choose.

All of that has worked just fine. Since the story appeared a bit over a week ago, two garages have offered us space.

This is Nathan Bolton and partner, Linda, going toGary’s garage at South Kincumber.
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Gary’s keen to help but, understandably, wondering where it all might lead. (As am I!)
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Says Gary, “This could be Olive’s corner. We’d get rid of all that junk of course….”
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But then, in came another offer. This one from The Throttle Shop in West Gosford
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The Throttle shop is a Repco garage which specializes in work on custom cars like this formidable looking beast
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Why, I wondered, was owner, Mike Madrusan so keen to play host, ready to give space for free, for this conversion?
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Yes, Mike, why?
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It turns out that he saw the film, Who Killed The Electric Car on Fox.

Mike was incensed to learn that a sensible and inspiring project like the EV1 electric car, had been killed off by GM and mainly because it was too successful.

Here’s the EV1 again for those who’ve not read the previous post.

(Go back and look for the whole story)
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Mike’s curious too, to find out how effective electric cars can be in Australia.

In theory, they are a simple mechanism. But how easy will it be to turn a petrol driven car into a sparker, locally?

This, by the way is the car to be converted, a tiny Daihatsu Sirion, 1999.

(That’s our Tosca standing guard beside the test car in case GM is snooping)
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Mike presently converts petrol cars to run on compressed gas and, while that’s a much simpler, it means he’s conversion minded in his day to day business.

Best of all, he’s ready to put his mechanics to work to help. I think The Throttle shop is the one.

But the challenge has just got a lot bigger than the one I put to Les . More of that later.

Let’s take a short break in out story here it have a look at a twike, made in Germany.

Here’s one which has found its way to the US, a human electric hybrid.
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Things were due to happen of which I had no inkling as I said goodbye to Mike, the light fading.
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That night I had a call from Les Puklowski.

Les is probably the most experienced converter in Australia. He’s converted 49 cars of all makes, and done so over many years.
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I had phoned him when I first got the idea but he was away.

Now, he was calling me back and saying he could do the whole job for an attractive price.

But he’d have to do it at his Windsor workshop, far from the Central Coast where I live.

And as you know, my goal is have the work done locally so that it’s accessible to the public

Hence, I’d chosen Nathan who was prepared to do the work here.

I say, was, because Nathan has now pulled out.

This came about in part because of something I discussed with Les. The type of batteries we’d use.

The night before, I had run the sums on what it would all cost.

Adding in the cost of the Sirion, which I bought for $4500, the total cost for my Sirion Olive, was going to be about $32,000.. The Lithium Ion batteries nathan proposed, really bumped it up.

It quickly became clear that, even if I got the expected 8 years working life out to the lithium Ion batteries, and even if I never used another drop of gas, there was no way the Sirion Olive could ever be a money saver.

I was torn, tormented. Even if I could afford the car as an experiment, how could I recommend this to you, the public? You’d think I was just a foolish dreamer.

Talking to Les, it became clear that the best idea was to use conventional lead acid batteries.

At a third of the price of the lithium Ion batteries they could make the conversion more affordable.

But they would also be
1. heavier..
2. give somewhat less range…
3. last not as long….

Lead Acid will bring the conversion cost down to the point that one would still lose money over 8 years, but a small enough amount to justify being a pioneer……I hope.

I put this to Nathan. Changing battery type was a mistake, he felt. He resigned.

With no builder, Les made me a quote. Here is his quote
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And here again is Nathan’s, the extra cost being essentially, the more expensive batteries and the management system they require, plus the freight of course.

Les’ Quote does not include key items that are in Nathan’s such as the aircon conversion, the battery racks, the cost of RTA inspection, etc. Direct comparison is not yet possible.
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Lithium Ion batteries, the controller needed, and the freight bump all up the cost. They are not made here. They have to come from China.

So, I’m going for regular batteries. I’m thinking my lead acid’s might well be replaceable by something better and cheaper quite soon.

Here are the calculations which set my alarm bells ringing on the Lithium Ion option .

Given the expected range of 50-80 kms, I would envisage we’d drive The Sirion Olive a maximum of 500 kms. a week.

Taking petrol at $1.50 a liter, this gives me a gas bill over 8 years of $18,720.

On top of that, I budget $1000 a year for repairs to a petrol car over the same period.

This gives me a total petrol car cost over the period of $26720.

Against this the Sirion Olive should cost the following .

(I’m calculating $2 a charge, 365 charges per year, though it may be more like an average of $1 a charge)

At $2 a day, this comes to $5840 over the 8 years.

To this, I add repairs to the Sirion Olive (much less than for a petrol car, tires, etc.) of $200 a year for a total $1600.

This makes total running costs for the Sirion Olive to be $7440 over 8 years.

Also, we must add $3000 for a new set of Lead acid batteries (or other) since these only last 4 years, max.

To the running costs, must be added the conversion costs which I’ve taken from Les’ budget, $17630,

This becomes $7440 +$17630 +$3000=$28070

This means a loss $1350 over the 8 year period. $28070 -$26720= $1350

Of course this does not take into account that the Sirion Olive is far less versatile.

Truly, if I don’t get a Kilometer range that works with our local lifestyle, then we will have made a really bad move.

Before I finally commit to going ahead, we need to do driving range tests with the car Les has recently completed. More of that later.

Our plan is to have two cars. A small petrol car for longer trips and the Sirion Olive for local runs.

Now what about the team? Can we put together a local group who will do the conversion for same price as Les Puklowski?

I went to see Les on his property at Windsor. It’s really rural!
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I found him tinkering with an electric car that he’s almost ready to deliver to a buyer.

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To my delight, it’s a conversion with lead acid batteries.

Here, Les shows 11 of such batteries, neatly tucked under the rear seat.

You don’t feel them under your bum, he assures me.
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And four more where the radiator used to be, for a total of 15 lead acid batteries of 12 volts each
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Also pleasing is the fact that this Daewoo been sold to a man in my area, Fred Lawrence who lives at Wyee.

This means that whoever does the conversion on the Central Coast, can use Les’ Daewoo as a model, and have access to it presumably.

I find I like Les a lot. Oh, it would be so easy to have him do the whole job.

He has two conversions on order. If he did do mine, I’d have to wait some months but then the job would surely be well done as well as cost contained.

But I do want to done locally. Torn, Torn. Torn!

Then, a break on the clouds, a very useful person makes contact.

He is John Rose who has spent many years as an electrical engineer, including designing and building electric vehicles for mining companies.

He’s now semi retired. Happy at home
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John’s also been giving a helping hand to a local, an old fella, Rick Smith, who’s been converting a VW Beetle.

Old age and financial strains have caught up with Rick and now his conversion, less batteries, is on the market for $10,000.

If you are interested in Rick’s car, leave a comment on this blog and I’ll put you in touch

I feel John Rose knows much of what we need to know and so I’m happy when he tells me he’s willing to come on as a consultant.

I met John when I went to see the Daewoo in it new home, Wyee, and with it’s new owner, Fred Lawrence.

Again, I found myself out in the sticks. These electric car people really love the back blocks, it seems!
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Here’s John and Fred. John’s the one on the right.
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Fred’s quite a character. He’s a semi retired bus driver.

I can just imagine him joking with a bus load of kids on the daily runs he used to do. He still drives buses some weekends

Later, as we go for a run and pass a gas station, Fred gives them the finger and cries. “Eat your hearts out, fellas!”
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John takes a look under the bonnet of the Daewoo and declares that Les has done an excellent conversion.
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It’s even worth some photos for the file.
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Fred plans to promote conversions with this car.

Les has given him a fact sheet for the window when he displays the Daewoo in supermarket car parks.

That, along with its tag, “I’m electric.” should attract interest.
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Fred anticipates having a lot of fun with this car, as well and making an important statement about the environment.

He’s aware, as are we all, that given how dirty coal fire generating stations are, at the moment we are displacing the problem.

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As we leave, Fred says he’s happy for his Daewoo to serve as a model.

He’ll let the people at the The Throttle shop, Mike and the boys, pore over it as much as they like.

He’ll also run range test for us . These are crucial for me in making my final decision, in deciding whether the Sirion Olive will be just an expensive toy or not.

For his part, John is prepared to draw up the engineering plans and a critical path, dates by which each part of the work must be done.

But he is unable at this time to do the hands on electrical work and that is crucial, that’s what’s new
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Enter Mark Hungerford.
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Mark saw the article in the paper and left me a message on my mobile.

“I’m interested and would like to help.”

I phoned back and found he was a “top sparkie” who works on golf carts, amongst other things.

He tunes them to get the best performance out of what are, of course, electric cars of limited speed.

I brought John and Mark together and listened as they had, what was to me, an incomprehensible conversation.

John declared the results to to be completely satisfactory in that, “Mark really knows his stuff.”
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We are guinea pigs, we know, and pay a price to hasten change. Will new batteries come soon?

Will there be other systems where one does not charge one’s batteries but exchange them in seconds so as to be able to keep on going as far as one likes?
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Isn’t that a clever idea?

Back to the Sirion Olive Here’s where we stand today, Folks.

1. John Rose will lay out the over all conversion, the targets to be met etc. He will also sign off on the car electrically.

He’ll give it it’s final inspection prior to its being inspected and passed by the RTA

2. Les Puklowski will supply all the parts and do the pre assembly work at Windsor. This will include making the battery boxes to measure for Sirion Olive.

As part of his fee, Les will get the Sirion petrol motor, which he wants for some reason.

3. Mike Madrusan at The Throttle Shop, will provide the workplace, pull out the petrol motor (going to Les) and install the replacement electric motor, all skilled mechanic jobs.

4. Mark Hungerford will install and test the electrical components. This will, most importantly, involve tuning the control system to the batteries and engine.

5. Fred Lawrence will make his is Daewoo available, within reason, so as to serve as a model for the work .

6. I will provide the finance. I will fund Les as per his budget. Mike is providing the space for free and hopefully, at a fixed reduced rate, the mechanical work.

The costs. John is providing his services for free. Mark is hopefully providing his help at a rate which does not take the total labor conversion costs over the $5000 that Les has estimated if he were to do the work.

I am hoping that all those in the team will leave comments on this blog to the effect that they are happy with their roles as envisaged.

This will form the basis of the contract between us, though there will be a more formal written document as well.

Any other comments from the team which might be interesting to the reader, are of course welcome.

I will, as well as footing the bills, be recording the whole process in stills and video.
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lastly, we will soon have public screenings of the Film, Who Killed the electric car?.

These will be at the Kariong Community hall on Woy Woy rd. and hopefully, at the Avoca beach Surf club.

Anyone else who wants to host a screening should contact me.

So, is it a go? Not yet completely sure but it’s looking good.

When I have doubts, I just let Olive sing her song!
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