Build a Hybrid

Fiero-hybrid retrofit project on track

2007-08-08T16:47:00.000-07:00

Even here in Michigan's Upper Peninsula near the cold waters of Lake Superior, this summer's heat wave has been remarkable. In spite of it, though, Ken has finished cutting, drilling, milling, grinding and painting the adaptor plates in our shop.

He also welded locating pins on the plates; these fit into the transmission & make it easier to line up. Next up: fabricating stand-offs (spacers, through which go high-strength threaded rods). Then we'll bolt parts together & make shafts. Aluminum for the stand-offs is on order.

At this point, most of the precision work is now completed. Throughout this prototyping project, we have also spent considerable time figuring out the commercialization process and details surrounding the DIY market for hybrid retrofits.

According to Ken, "It takes a lot of precision work to get a really good product. Once commercialized, it will be simpler."

Eagle HEV retrofit project begins

2007-08-07T17:15:00.000-07:00

Work began this month on Randall's future wheels. Although he is only 13 years old, he's determined to learn all he can from the experts.

"I want my first car to be a hybrid!" is a great attitude to build a future on.

Innovative Adaptor Plate in Progress

2007-07-13T15:42:00.000-07:00

We're right on schedule with our Fiero-hybrid retrofit project. Removal of the engine, transmission and assorted pieces/parts went smoothly. In fact, we were able to lift the engine & transmission together in one operation.

Underway in the shop now is the completion of the adaptor plate. Ken used a portable hacksaw to cut the 3/16" steel plate and is now drilling holes to mount components to the transmission (motor, generator, belt drive, etc.).

This adaptor plate design is unique; it will hold both generator & motor on a single plate.

According to Ken, the time-consuming part was measuring and drawing the template. Next up... populating the parts on the plates prior to installing in the Fiero.

Definition of a True Hybrid

2007-06-18T13:38:00.000-07:00

What is a TRUE hybrid? It's the best of both worlds.

Sad to say, most of the OEMs are following Toyota's lead in their rush to sell "partial hybrids". Partial hybrids are electrically-assisted or enhanced mechanical drive systems. Whenever there is a direct connection between the internal combustion engine and the wheels, you're looking at a mechanically driven system with electrical enhancements.

A true hybrid uses equal parts of a combustion engine and either electric or hydraulic pumps, generators & motors. In other words, true hybrids fall between mechanically-driven cars and electrically-driven vehicles - using a 50/50 mix of parts. This approach means that you can run the ICE and all other components at their BEP (best efficiency point) greater than 90% of the time, under all load conditions.

By capturing energy & using it at BEP, this design strategy delivers what we're looking for:

much higher MPG,
less pollution
better overall efficiencies.

In fact, we believe that true hybrids represent the only system that can enable us to cut vehicle emissions by 50% before the global warming "point of no return".

The Convert-to-HEV Revolution has Begun

2007-05-23T20:03:00.000-07:00

Leading climate change scientists are calling for 50% reductions in our emissions - NOW. We took up the gauntlet and are preparing DIY hybrid vehicle conversion plans for those who love their cars, but not their fuel bills.

This month we began to prototype a high-mileage hybrid vehicle using our powerful new power management strategy. We've already received signups for our Convert-to-HEV Plans at www.phoenixnavigation.com/hybrids/feedback.htm

Have you checked it out yet?

As we proceed with our Pontiac Fiero conversion, we'll post news & photos on this site for all to share. Looking for your feedback.