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Electric Vehicle Conversion Kit

Home Page Electric Vehicle Conversion Kit Hybrid Electric-Gas Vehicle Conversion Custom Electric Conversion FAQ About Roy Kaylor

Roy's 1982 EV & EV-H early prototypes were acquired by Toyota Motor Corp. Kaylor-Kit EVs (electric vehicles) go 70 city miles at 40 m.p.h. <> Kaylor EV-Hs (hybrids) range 50-100 m.p.g., go 500 to 1,000 freeway miles at 55-65 m.p.h. on 10 gallons of fuel, a 12-20 horsepower auxiliary gas or diesel engine driving two generators charges 12 batteries powering a compact electric motor.

Proven technology at an affordable price

This electric car conversion kit is for VW rear transaxle-based vehicles, including Beetles and Porsche 914. It is perfect for light vehicles like VW bugs, dune buggies or our custom fiberglass bodies on a VW chassis. The kit comes with a powerful, peak 30 HP, shunt motor that prevents motor overspeeding including a fully functional clutch. This lets you use a full range of gears in the transaxle. This kit has two main assemblies: A motor/adapter plate/cooling fan that is easily mounted to the VW transaxile with four bolts; and the second assembly is the control board populated with heavy-duty mil spec power relays and other control electronics.

  

Traction Motor Assembly The key to this kit is the China-2 motor and its optional 12 horsepower gas powered auxilliary engine used to drive two generators (a military surplus 400 Amp Mil Spec Aircraft Quality starter generator may be substituted). Because Kaylor-Kit motors are designed to be both a starter and a generator, you can achieve practical regenerative breaking levels that are not possible with a series motor. The aircraft generator does this because it is a shunt motor. When stopping or going down hill you put energy back into the batteries. Using regenerative breaking for down hill grades also provides a huge safety advantage over cars that have only hydraulic breaks. This is especially true when you carry the heavy batteries used in EVs.

Aircraft generators have another advantage because they are light. Designed to work in an aircraft these aviation starters give you one of the best 'punch for motor pounds' of any traction motor used today. These generators are cooled with an external fan so even when you are lugging the motor you get maximum airflow at all times.

Aircraft motors have an amazing high upper RPM. At 72 volts an aircraft generator achieves 7,200 RPM. These motors can reach 10,000 to 12,000 RPM for short periods of time. Much of this high RPM capability comes from the Mil Spec steel wrapped armature.

At the heart of the kit is an elegantly engineered aluminum adapter plate (some plates are free of manufacturers logo). This plate interfaces aircraft propulsion technology to a rear wheel drive VW transaxile. At the center of the adapter plate are two massive bearings that hold the center core hub. This hub supports a lightened flywheel, pressure plate and clutch assembly. The use of a clutch with a shunt motor allows for a smooth transition from one incremental speed to another. Since shunt motors won't over speed and run away when running freely the clutch also provides an additional emergency disconnect, a valuable safety feature. For the interface to the shunt motor the adapter plate has a standard 6-inch bolt circle and a 7/8-inch female spline.


The Control board Assembly The second Assembly (the control board) taps the battery and gives you two-step voltage speed control. This gives you a high speed and a low speed for each gear you may be in. The series of incremental speed settings gives you exactly the same feeling as riding in a high performance gas powered sports car. Unlike transistorized controllers, using relays with a shunt motor gives you automatic regen without any additional hardware. Also, relays are a more forgiving technology in case of controller failure. Transistorized controllers can rack up over $900 in transistor replacement costs in milliseconds so they are not used in our design. The control board consists of a main double-pole double-throw relay. This relay gives you a two step voltage or power level for each mechanical gear you are in. The control board also has the main single-pole single-throw on/off power relay. Mounted on the control board is also a heavily heat sunk charge bypass diode and the 12 volt control unit.


Ease of assembly Both the traction motor and control board Assemblies come ready to hook up. The only major things you need to add are traction batteries. Batteries recommended are 6 volt, deep discharge, lead-acid golf cart batteries. At many locations in the country you can buy used golf cart batteries at little more than their core recycle value.

All the components provided come complete with terminal ends that are ready to be crimped to common '00' welding cable you can get at any welding supply store. You need to pick the type of terminal ends for your type of battery posts. This depends on what style battery you decide to use. All terminal ends are clearly labeled so you can cross reference them to the system schematic provided. It is as simple as putting tab 'A' into slot 'B'.

 

Relays Verses Transistorized Control As a professional consultant in EV propulsion for on-road, off-road, automobile, motorcycle, race, marine, flight and aerospace applications, I have designed many types control technologies. For the over 50 years I have worked in the EV field.. Relays are cheaper, more reliable, easy to fix, and more efficient in operation. A relay does not have the voltage drop that is inherent in all semiconductor devices like a transistor. Over a decade ago a member of the nations largest electric auto association, Bruce Mckasky, won the National Range and endurance Rally 5 years in a row. Mackasky competed against new high-end series motors with advanced transistorized controllers and year after year brought them down to defeat. Each year his vehicle would beat his past record until he finally reached a range of 127.5 miles on a single charge. Mckasky's vehicle was a simple VW based dunebuggy powered by an aircraft generator. His adapter plate was identical to the one included in this kit and he used the same two-voltage step relay control scheme. The bottom line is just because something is new, does not automatically make it better. When you consider that some EV kits cost between $7,000 to $9,000 a classic electro mechanical system looks pretty good.


Kit Content Listing

Traction Motor Assembly

  • Shunt wound traction motor.
  • Shunt motor cooling fan.
  • Shunt motor anti arch diode.
  • Cooling fan adapter and hookup hose.
  • Propulsion motor adapter plate for VW rear transaxile type vehicle.
  • Adapter plate center core hub and bearings.
  • Light weight flywheel, pressure plate and clutch disk.
  • VW gland nut with pilot shaft bearing.

Control Plate Assembly

  • Main double throw double pole mechanically interlocked voltage stepping power control relay.
  • Single pole single throw main on / off power relay.
  • 800 Amp 50 mv shunt.
  • Fined heat sunk charge bypass diode.
  • 12 Volt Control Unit. Interfaces cars existing 12 volt electrical system with high voltage main pack power control relays.

Separately mounted components, etc

  • Main Volt Meter.
  • Main Amp Meter.
  • Main "off-on-on" speed / voltage control switch.
  • On-board 72 Volt primary and opportunity battery charger system. 120 VAC input. 72 VDC output.
  • Easy to follow electrical schematic of system.