Re: range complaints?

["Nelson Family" <rnelson@ro.com>]

Eric,
If it gets too difficult for you to handle, post the car for sale.  I'm sure
others on the list, myself included, would be interested.  Perhaps a trade
for a more dependable ICE could be arranged.

Rick Nelson

-----Original Message-----
From: eric.chang@chrysalis.org <eric.chang@chrysalis.org>
To: ev@listproc.sjsu.edu <ev@listproc.sjsu.edu>
Date: Monday, June 29, 1998 7:55 AM
Subject: range complaints?


>
>Hi.  I noticed the discussion about the inadequacy of range of
>electric vehicles.  It was mentioned that 50 miles range is not
>enough.  It is not this way with me.  I would get along really
>well with 20 miles range.  Our feet have a very limited range
>for walking.  Most people only walk a couple miles a day, but
>this is enough to get them pretty far, not to mention save a
>lot of gas and parking hassles.
>
>My real problem with the electric car is that it is unreliable
>and inconvenient.  First it was the controller.  That was not
>so bad, since electronics does not scare me as much as other
>things.  Then, the batteries died.  They did not die slowly
>and quietly, but instead they died suddenly and violently,
>with a spectacular single cell failure that reversed and
>subsequently belched steam and acid.  It was fortunate that
>it was possible to open the cell caps and check for bad cells
>with a hydrometer, since only two of the batteries turned out
>to be bad.  After replacing these two batteries, one of which
>(the sorriest one) had a hole melted in its top, costing one
>pair of pants, the car achieved its full range.  Since the
>commute distance is only 3 miles, and good electronics parts
>stores, libraries, and restaurants may be found within 5-7
>miles, it was hard to exceed this range on the weekdays.  Of
>course, there were longer trips on the weekends, but the ICE
>car was always ready for that.
>
>Except for the slow performance, which could be gotten used
>to, the car was pretty fun to drive.  And, it was great for
>trips to the grocery, video, etc.  As a bonus, the mileage on
>the ICE car improved, since there were less short trips.  The
>final part to break down was the motor.  Accidentally leaving
>it in second gear on a 60 mph surge down the expressway caused
>some of the retaining bands to snap, resulting in a harrowing
>(and even slower ride home).
>
>Because of the voodoo engineering that the car was put
>together with, it was almost impossible to get the motor out.
>The battery box, along with all the batteries in front, had
>to be removed.  After this was lifted, it revealed a plate
>on the motor giving the maximum RPM.  Alas, too little, too
>late.  Even at this time, it was not known that it was the
>motor that failed, since the rear ventilation assembly could
>not be removed yet.  In fact, the arrogant designers of the
>car, assuming that the motor would last "forever", riveted
>in the battery box, so the rivets had to be drilled.
>
>This was not the end of the trouble.  It was incredibly
>difficult, even with a block and tackle, and the assistance
>of another person, to remove the motor.  It turns out that
>the adapter plate was made in two pieces, and the inner ring
>was not cut to allow passage of the drive hubs.  This made
>it impossible to remove the motor without removing the hub.
>In addition, since there was so little room to see, this took
>hours to figure out.  Finally, after removing the hub
>(resulting in one broken puller), the motor could come out.
>
>Many people recommended that it be taken to a motor rewinding
>shop.  On one of the EV www sites, there was a link going to
>Shoemaker Electric.  They said that they were too far away, so
>they recommended another EASA (Electrical Apparatus Service
>Association) member in the neighborhood.  When I called the
>local place, the service manager gave me a dire warning that
>the cost to refurbish the motor could be nearly unlimited.
>Since it would cost about $3000 to get another brand of motor
>and an adapter plate (a new one would probably be required),
>that would be an upper limit.  They were not sure, without
>looking at the motor, whether they could stay within that
>limit.  Actually, the hassle of getting a custom adapter
>plate was probably worth even more.
>
>Anyway, when they took a look at the motor, the service
>manager said that they could not tell anything just from
>looking at the commutator.  They would have to bake, spin
>test and resistance test the armature.  That would cost
>money, and then maybe they could tell me what a refurbish
>job would cost.
>
>After over a week in the shop,  I decided to call to see if
>they had taken a look at it or not.  A silly sounding woman
>answered the phone and said that it was completely dissambled
>and both end bells were off.  This sounded good, almost too
>good to be true.  I then asked if she was sure, and she was
>quiet for a long time.  Finally, she admitted that she was
>not sure and reluctantly agreed to go back and take a look.
>It turned out to be in exactly the same state that I took it
>in.  I called back half an hour before closing time on Friday
>afternoon, and the same silly woman was laughing up a storm.
>Apparently the guy who was responsible was busy, and would
>get back to me before closing time if I was lucky.  Anyway,
>just before closing time, there was no call, so I called back.
>I got an answering machine with a stern warning not to try
>to call during non-business hours.
>
>I called the following Monday, and was told not to call back
>until Wednesday.  Then, when I called on Wednesday, they told
>me to try back Friday.  Remember, this is just for diagnosis,
>not repair.  Meanwhile, the electric car has been sitting,
>motionless and motorless.  Damage done to the oil seal on the
>drive hub from yanking in vain has caused all the gear oil to
>leak onto the pavement.  A new seal had to be special
>ordered, since the original car is kind of rare.  Also, a
>seal puller, and an installer were purchased.
>
>These motors are so hard and mysterious.  No repair manuals
>are available.  It is not like rebuilding an engine.  One is
>at the mercy of unknown and unrecommended motor repair shops
>which are, in many ways, like the sleazy auto repair shops,
>but without friends with ICE cars to warn you away from them.
>Eventually, it will probably be necessary to find a way to
>perform a home repair on the motor, or buy a new one.
>
>Range?  50 miles?  20 miles?  Naah, not a problem.
>
>Eric
>