Woody's 1963 Ford Cortina
- woody
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- Real Name: Anthony Wood
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Woody's 1963 Ford Cortina
The Cortina moved under it's own (ICE) power today for the first time in 3 years. So I guess that's as good a starting point to declare as any.
This post will be replaced with table of contents as per the guidelines, but for now will just be a sketch of what will go here.
cheers,
Woody
Aims:
1. Fun to drive
2. Practical for daily use
3. Minimal modifications to structure
4. Roughly break even dollarwise in the long term, discounting own time spent
Why this car:
1. We have owned it since 1994 and love it
2. It is light (800kg)
3. No ICE-powered accessories (heater, brake booster, steering, aircon) - only have to make the car go
4. easy to improve on performance (0-100 in 26 seconds when new)
5. rear wheel drive, front engined
The parts:
1. Industrial A/C components like acmotor, a4x4kiwi, Johny
2. ABB 132-316HSE 4 pole 240V 50Hz motor (ordered)
3. Industrial VFD around 55kW e.g. Telemecanique ATV71-HD55N4
4. 10-20 Ah of LiFePO4 200-225S 1-2P e.g. Headway, EVPST, TS
The plan:
1. Emotor in engine bay, partially in transmission tunnel
2. Direct to diff drive via modified sliding spline tailshaft - no gearbox
3. Batteries (75-150kg) under boot and/or behind wheels. Fuel tank in boot floor bolts out, leaving hole for battery access.
4. VFD under parcel shelf behind rear seats.
5. Split batteries into safe voltages, maybe 48-72V with contactors.
6. Charge either 1 fat charger in parallel via diodes or multiple chargers of low voltage, each charging 1 or more packs.
7. BMS - leaning towards Nevilleh BMS because micro is flexible.
8. Range Extender Trailer- original ICE + 2pole ACIM + small VFD
The timeline (slow):
1. Plan to re-register car running original ICE ASAP
2. Work out when the rest can happen, I plan to have it registered during conversion so that I can road test it legally.
Progress (slow)
21/12/2009: ABB 132-316 HSE is ordered, I expect sometime in the first half of next year.
26/12/2009: Car is running again under ICE power, some brakes siezed, thermostat probably stuck (overheats real quick)
27/12/2009: thermostat replaced, radiator flushed - seems OK now.
4/1/2010: had planned to register by now - brakes + steering fixed but rust is non-trivial
6/2/2010: started rust work on dodgy passenger side sill
Edits:
2009-12-27: added up range extender trailer details
2010-02-09: progress 4/1 + 6/2
This post will be replaced with table of contents as per the guidelines, but for now will just be a sketch of what will go here.
cheers,
Woody
Aims:
1. Fun to drive
2. Practical for daily use
3. Minimal modifications to structure
4. Roughly break even dollarwise in the long term, discounting own time spent
Why this car:
1. We have owned it since 1994 and love it
2. It is light (800kg)
3. No ICE-powered accessories (heater, brake booster, steering, aircon) - only have to make the car go
4. easy to improve on performance (0-100 in 26 seconds when new)
5. rear wheel drive, front engined
The parts:
1. Industrial A/C components like acmotor, a4x4kiwi, Johny
2. ABB 132-316HSE 4 pole 240V 50Hz motor (ordered)
3. Industrial VFD around 55kW e.g. Telemecanique ATV71-HD55N4
4. 10-20 Ah of LiFePO4 200-225S 1-2P e.g. Headway, EVPST, TS
The plan:
1. Emotor in engine bay, partially in transmission tunnel
2. Direct to diff drive via modified sliding spline tailshaft - no gearbox
3. Batteries (75-150kg) under boot and/or behind wheels. Fuel tank in boot floor bolts out, leaving hole for battery access.
4. VFD under parcel shelf behind rear seats.
5. Split batteries into safe voltages, maybe 48-72V with contactors.
6. Charge either 1 fat charger in parallel via diodes or multiple chargers of low voltage, each charging 1 or more packs.
7. BMS - leaning towards Nevilleh BMS because micro is flexible.
8. Range Extender Trailer- original ICE + 2pole ACIM + small VFD
The timeline (slow):
1. Plan to re-register car running original ICE ASAP
2. Work out when the rest can happen, I plan to have it registered during conversion so that I can road test it legally.
Progress (slow)
21/12/2009: ABB 132-316 HSE is ordered, I expect sometime in the first half of next year.
26/12/2009: Car is running again under ICE power, some brakes siezed, thermostat probably stuck (overheats real quick)
27/12/2009: thermostat replaced, radiator flushed - seems OK now.
4/1/2010: had planned to register by now - brakes + steering fixed but rust is non-trivial
6/2/2010: started rust work on dodgy passenger side sill
Edits:
2009-12-27: added up range extender trailer details
2010-02-09: progress 4/1 + 6/2
Last edited by woody on Mon, 08 Feb 2010, 18:18, edited 1 time in total.
Planned EV: '63 Cortina using AC and LiFePO4 Battery Pack
- coulomb
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Woody's 1963 Ford Cortina
Congrats, Woody!
So you're keeping the original ICE, since the whole car is so light, and will be using a 2-pole induction machine as a generator for range extension? Neat!
I couldn't help a little AC motor comparison here; sorry I couldn't find a reliable catalogue with all 3 motors in it (the Combined Asia Region seems to disagree with others over important details).

The heavier motor is the most efficient, though it's extra 66 kg (compared to the other 22 kW motor) adds some 5% to the weight of a 1300 kg vehicle, or 3.3% to a 2000 kg vehicle. For 2.1% more efficiency, it's not looking such a bad deal, considering that regen reduces the weight penalty somewhat.
It's interesting that the 4-pole motors have heavier (higher inertia) rotors. Woody's motor is ~~ 30/22 ~= 1.3 times more powerful at 2900 RPM; scaling the rotor would yield 0.033, still only 65% of the 4-pole's inertia. Acmotor's is almost 9x the inertia.
I'm intrigued that our 22 kW has the highest power factor of these motors. So we'll be using a slightly greater proportion of inverter current to power the wheels, rather than energise the field. Of course, that situation could well change when the motor is overloaded.
So you're keeping the original ICE, since the whole car is so light, and will be using a 2-pole induction machine as a generator for range extension? Neat!
I couldn't help a little AC motor comparison here; sorry I couldn't find a reliable catalogue with all 3 motors in it (the Combined Asia Region seems to disagree with others over important details).

The heavier motor is the most efficient, though it's extra 66 kg (compared to the other 22 kW motor) adds some 5% to the weight of a 1300 kg vehicle, or 3.3% to a 2000 kg vehicle. For 2.1% more efficiency, it's not looking such a bad deal, considering that regen reduces the weight penalty somewhat.
It's interesting that the 4-pole motors have heavier (higher inertia) rotors. Woody's motor is ~~ 30/22 ~= 1.3 times more powerful at 2900 RPM; scaling the rotor would yield 0.033, still only 65% of the 4-pole's inertia. Acmotor's is almost 9x the inertia.
I'm intrigued that our 22 kW has the highest power factor of these motors. So we'll be using a slightly greater proportion of inverter current to power the wheels, rather than energise the field. Of course, that situation could well change when the motor is overloaded.
Nissan Leaf 2012 with new battery May 2019.
5650 W solar, 2xPIP-4048MS inverters, 16 kWh battery.
1.4 kW solar with 1.2 kW Latronics inverter and FIT.
160 W solar, 2.5 kWh 24 V battery for lights.
Patching PIP-4048/5048 inverter-chargers.
5650 W solar, 2xPIP-4048MS inverters, 16 kWh battery.
1.4 kW solar with 1.2 kW Latronics inverter and FIT.
160 W solar, 2.5 kWh 24 V battery for lights.
Patching PIP-4048/5048 inverter-chargers.
- woody
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Woody's 1963 Ford Cortina
I've clarified a bit more above, I want to mount the original ICE, radiator, fuel tank, etc on a small trailer together with the small 2 pole and VFD (15kw?), plug into the 600V bus and use it for longer trips. This will keep the ICE servicable and be cheap / easy / cool.coulomb wrote: Congrats, Woody!
So you're keeping the original ICE, since the whole car is so light, and will be using a 2-pole induction machine as a generator for range extension? Neat!
The power factor only holds for the nominal speed/load according to the ABB formulas - power factor goes up with load, but the VFD does tricky things like lowering V/F for better efficiency so who knows?I'm intrigued that our 22 kW has the highest power factor of these motors. So we'll be using a slightly greater proportion of inverter current to power the wheels, rather than energise the field. Of course, that situation could well change when the motor is overloaded.
Planned EV: '63 Cortina using AC and LiFePO4 Battery Pack
- acmotor
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Woody's 1963 Ford Cortina
Woody, great to see the 'member's machine' Keep us posted.
Coulomb, this is interesting comparison. The HO specs look good.
Can you add in the gearbox/adaptor plate weight and gearbox efficiency as these are telling factors when trying to compare DD to GB systems.
I think the overall weight will come closer though still be in the 2 pole favour, but the efficiency difference will be massivly in the 4 pole DD favour.
Ts/Tn has no relevance to EV use. Unless you plan to get the VFD setup wrong and pull 360A at 50Hz with locked rotor !!
BTW, the actual data for my 22kW from data sheet supplied with motor is...
(Ask for the 3 page technical data shhet that comes in .xls format from ABB)
Product TEFC, 3-phase, squirrel cage induction motor
Product code 3GAA 182 102-ADC
Type/Frame M3AA 180 L 4
Mounting IM1001, B3(foot)
Rated output PN 22 kW
Rated voltage UN 415 VD ± 5 % (IEC 60034-1)
Rated frequency fN 50 Hz ± 2 % (IEC 60034-1)
Rated speed nN 1475 r/min
Rated current IN 39 A
No-load current 14.5 A
Starting current Is/IN 7.5
Nominal torque TN 142 Nm
Locked rotor torque TS/TN 2.8
Maximum torque Tmax/TN 3.1
Load characteristics (IEC 60034-2)
Load % Current A Efficiency %Power factor
100 39 93.3 0.84
75 31 93.9 0.8
50 23 93.6 0.71
25 16 91.8 0.52
Maximum starting time from hot 15 s
Maximum starting time from cold 27 s
Insulation class / Temperature class F / B
Ambient temperature 40 °C
Enclosure IP55
Cooling system IC411 self ventilated
Sound pressure level (LP dB(A) 1m) 63 dB(A) at load
Moment of inertia J = ¼ GD2 0.225 kg-m2
Weight of rotor 61 kg
Total weight of motor 161 kg
Noteably, these 'world market' motors have many different spec numbers listed for different markets so close comparison may be difficult.
You guys have the lower voltage delta versions that should work out well.
Coulomb, this is interesting comparison. The HO specs look good.
Can you add in the gearbox/adaptor plate weight and gearbox efficiency as these are telling factors when trying to compare DD to GB systems.
I think the overall weight will come closer though still be in the 2 pole favour, but the efficiency difference will be massivly in the 4 pole DD favour.
Ts/Tn has no relevance to EV use. Unless you plan to get the VFD setup wrong and pull 360A at 50Hz with locked rotor !!
BTW, the actual data for my 22kW from data sheet supplied with motor is...
(Ask for the 3 page technical data shhet that comes in .xls format from ABB)
Product TEFC, 3-phase, squirrel cage induction motor
Product code 3GAA 182 102-ADC
Type/Frame M3AA 180 L 4
Mounting IM1001, B3(foot)
Rated output PN 22 kW
Rated voltage UN 415 VD ± 5 % (IEC 60034-1)
Rated frequency fN 50 Hz ± 2 % (IEC 60034-1)
Rated speed nN 1475 r/min
Rated current IN 39 A
No-load current 14.5 A
Starting current Is/IN 7.5
Nominal torque TN 142 Nm
Locked rotor torque TS/TN 2.8
Maximum torque Tmax/TN 3.1
Load characteristics (IEC 60034-2)
Load % Current A Efficiency %Power factor
100 39 93.3 0.84
75 31 93.9 0.8
50 23 93.6 0.71
25 16 91.8 0.52
Maximum starting time from hot 15 s
Maximum starting time from cold 27 s
Insulation class / Temperature class F / B
Ambient temperature 40 °C
Enclosure IP55
Cooling system IC411 self ventilated
Sound pressure level (LP dB(A) 1m) 63 dB(A) at load
Moment of inertia J = ¼ GD2 0.225 kg-m2
Weight of rotor 61 kg
Total weight of motor 161 kg
Noteably, these 'world market' motors have many different spec numbers listed for different markets so close comparison may be difficult.
You guys have the lower voltage delta versions that should work out well.
iMiEV MY12 110,230km in pure Electric and loving it !
- Richo
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Woody's 1963 Ford Cortina
So what did they say was the lead time for the motor?
- woody
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- Real Name: Anthony Wood
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Woody's 1963 Ford Cortina
I think the quote said 6 weeks manufacturing + 8 weeks shipping.
Planned EV: '63 Cortina using AC and LiFePO4 Battery Pack
- Richo
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Woody's 1963 Ford Cortina
That seems better than before.
Maybe last years down turn has improved times.
Maybe last years down turn has improved times.
- woody
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Woody's 1963 Ford Cortina
Started some rust repairs on the weekend.
Flikr
Highly recommend not letting your car get rusty.
Edit: midnight grammar
Flikr
Highly recommend not letting your car get rusty.
Edit: midnight grammar
Last edited by woody on Mon, 08 Feb 2010, 18:16, edited 1 time in total.
Planned EV: '63 Cortina using AC and LiFePO4 Battery Pack
- Johny
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Woody's 1963 Ford Cortina
Really great to see reverse entropy in progress.
- woody
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- Real Name: Anthony Wood
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Woody's 1963 Ford Cortina
Entropy reversal almost complete!




Planned EV: '63 Cortina using AC and LiFePO4 Battery Pack
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Woody's 1963 Ford Cortina
Woody, are you using "zinc anneal" sheet for you repair panels? Looks a bit like it. I used to use it when I was keeping my X1/9 on the road and always wondered if it was the right material.
- woody
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Woody's 1963 Ford Cortina
Squiggles - the inner sill and other dabbed bits were scraps from a dishwasher or similar - so probably what you said, but no real thought went into that on my part, it's just what we had!
The outer sill (dark grey primer) was bought as a pre-bent "Sill Repair Panel" from a cortina specialist in melbourne ($50).
The guard repair section (Black) was bought from a Sydney ford specialist for $75.
I did get a chance to lie under the car with a ruler, and have a good look at everything...
SOGOS (Sawn Off Gearbox Output Shaft) is getting legs as a motor - tailshaft interface because:
1) it's a BOGOS (Bolt Off ...)
2) includes gearbox mount
3) looks like enough length between BOGOS and steering to fit motor and coupler
4) other SOGOS advantages like speedo drive, sliding spline mean I don't have to get a custom tailshaft or fit the guts of an electronic speedo into my mechanical speedo.
Also there will be plenty of room under the bonnet for the motor and controller, or the motor and an Esky.
The column shift output has 3 cables, which I am led to believe are push-pull for 1st-2nd, 3rd-4th, and reverse. So I should be able to make something simple to keep the approximate feel of the column shift. My current plan is to use the gear lever for electric reverse, and the different gear positions will give different amounts of engine braking.
The outer sill (dark grey primer) was bought as a pre-bent "Sill Repair Panel" from a cortina specialist in melbourne ($50).
The guard repair section (Black) was bought from a Sydney ford specialist for $75.
I did get a chance to lie under the car with a ruler, and have a good look at everything...
SOGOS (Sawn Off Gearbox Output Shaft) is getting legs as a motor - tailshaft interface because:
1) it's a BOGOS (Bolt Off ...)
2) includes gearbox mount
3) looks like enough length between BOGOS and steering to fit motor and coupler
4) other SOGOS advantages like speedo drive, sliding spline mean I don't have to get a custom tailshaft or fit the guts of an electronic speedo into my mechanical speedo.
Also there will be plenty of room under the bonnet for the motor and controller, or the motor and an Esky.
The column shift output has 3 cables, which I am led to believe are push-pull for 1st-2nd, 3rd-4th, and reverse. So I should be able to make something simple to keep the approximate feel of the column shift. My current plan is to use the gear lever for electric reverse, and the different gear positions will give different amounts of engine braking.
Last edited by woody on Mon, 01 Mar 2010, 17:27, edited 1 time in total.
Planned EV: '63 Cortina using AC and LiFePO4 Battery Pack
- woody
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Woody's 1963 Ford Cortina
Quick Update: the car is re-registered and on the road under petrol power - much thanks to Electrocycle for lots of help on Thursday + Friday last week with brake dramas.
Blue slip, rego + drive to Wamberal (60km) on Saturday morning, return journey Sunday afternoon. No major dramas.
Blue slip, rego + drive to Wamberal (60km) on Saturday morning, return journey Sunday afternoon. No major dramas.
Planned EV: '63 Cortina using AC and LiFePO4 Battery Pack
- Johny
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Woody's 1963 Ford Cortina
Great! Are you going to leave it petrol for a while or start the rip-out soon?
- woody
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Woody's 1963 Ford Cortina
I'm planning on gettIng all the bits I think I need first, get it all working as best I can outside the car, then pull it apart, possibly waiting for rego renewal if it's close.
Possible exception is batteries, I have 3 phase to my house.
I also have to fix up the drivers side doors, save up some pocket money, wait for ABB to build my motor, raise a family, etc.
Possible exception is batteries, I have 3 phase to my house.
I also have to fix up the drivers side doors, save up some pocket money, wait for ABB to build my motor, raise a family, etc.

Planned EV: '63 Cortina using AC and LiFePO4 Battery Pack
- Johny
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Woody's 1963 Ford Cortina
Yes, that seems like a good way to go. I guess I have spent the last 18 months collecting bits and I thought I was going fast! This assembly stage is dragging but the house and family tends to take precedence, as it should.
Anyways, good to see that the Cortina has started it's new life.
Anyways, good to see that the Cortina has started it's new life.
-
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Woody's 1963 Ford Cortina
Drove behind you today in my ev and your car is in lovely retro shape....will be even better without the ICE! I knew it was you due to the nicely done rust repair.....
- woody
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- Real Name: Anthony Wood
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Woody's 1963 Ford Cortina
I _really_ need to get some paint onto that...Lester wrote: Drove behind you today in my ev and your car is in lovely retro shape....will be even better without the ICE! I knew it was you due to the nicely done rust repair.....
Please honk + wave next time

We'll have to invent an international hand signal for EV!
Planned EV: '63 Cortina using AC and LiFePO4 Battery Pack
- woody
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- Real Name: Anthony Wood
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Woody's 1963 Ford Cortina
I chased up my motor supplier and my ETA is "pretty firm" as June 7th, so 12 weeks from now 

Planned EV: '63 Cortina using AC and LiFePO4 Battery Pack
- woody
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- Joined: Sat, 21 Jun 2008, 02:03
- Real Name: Anthony Wood
- Location: Mt Colah
Woody's 1963 Ford Cortina
I am informed that my motor is now in Bangkok - should be here next week.woody wrote: I chased up my motor supplier and my ETA is "pretty firm" as June 7th, so 12 weeks from now
Final Order Details:
3GAA132007-HSE
MOTOR 18.5KW 4P M3AA132SMD
FOOT/FLG B35
HIGH OUTPUT DESIGN
M3AA132SMD 4 HO 18.5kw 110V DD, 220 VD, 50Hz,
+142 12 terminal connection
122 x 2.6 = 317Nm.
Planned EV: '63 Cortina using AC and LiFePO4 Battery Pack
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Woody's 1963 Ford Cortina
wahoo. 

- Johny
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Woody's 1963 Ford Cortina
Great - then the fun can start.woody wrote: - should be here next week.
- woody
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- Real Name: Anthony Wood
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Woody's 1963 Ford Cortina
Motor is in the country (Control Techniques - Brisbane) and paid for!
Here is a progress photo showing my generator trailer and how much work I've been able to get done since I bought it.

Here is a progress photo showing my generator trailer and how much work I've been able to get done since I bought it.
Planned EV: '63 Cortina using AC and LiFePO4 Battery Pack
- Johny
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Woody's 1963 Ford Cortina
Ha ha. It took me a moment to get it.
- Speedily
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Woody's 1963 Ford Cortina
If you trim that the right way it would just about look like a generator on a trailer 
