Raffle Time!

It's time for the Topsail Electric Vehicle Annual Raffle!
We have big plans for next year's team, including an all-new conversion and significant updates to our other vehicles, but none of it will be possible without financial support.

We have over $2,100 in total prizes available, including...

Recliner from Hampstead Furniture
iPad Mini.
Ukulele from the Ukulele Academy
Car Detailing and Oil Change at Jeff Gordon Chevrolet
Car Detailing at Stevenson Honda
Oil Change and Car Wash at Wilmington Motor Works
Alignment and Tire Rotation at MS Auto
Massage and Facial from Innis Spa
Fishing Rod from Eastern Outfitters
Video Sunglasses from Surf City Pier
Gift Certificates to numerous restaurants and businesses, including:
Advance Auto, Camino Real, Dunkin Donuts, Englese's, Fuzzy Peach, Highway 55, Jungle Rapids, Long Horn, NY Corner Deli, Pizza Hut and Reel Pizza.

Tickets are $10, or 3 for $25, and may be purchased at the drawing.

The drawing will be held May 28th at 6:00PM in the EV Shop (located behind Topsail High School.

Introducing the Voltswagen!!

We are proud to announce the completion of our latest vehicle, a 1961 VW Bug, the Voltswagen, just in time for Mr. Garrett's 50th birthday!  The car belongs to Mr. Garrett, our former instructor, who was just named Executive Director of the EV Challenge.  In addition to everyday use, he will use this vehicle as a tool for recruiting new schools to participate in the EV Challenge. 

Some students stayed late into the night to get it finished!

The front battery box; charger is underneath.

The rear battery box, on the package shelf.

Plugged in and charging!

She's ready to go!

The Motor, controller and DC/DC converter.

Details of the car are as follows:

44 100 Ah Thundersky Cells
Lithiumate Lite BMS
Elcon PFC 1500 Charger
DCP Raptor 1200A Controller
ADC 9" Motor
Battery heaters
Range:  75 miles projected
Top Speed: Faster than stock
Acceleration: MUCH faster than stock

Raffle Time

It's time for the annual spring Fundraiser Raffle.  We have a lot of great things planned for next year, but none of it is possible without your financial support.

You can win one of over $2,000 in prizes:

iPad Mini
Dyson Hand Vac
Side Arm Paddleboard Lessons
Surf City Pier Season Pass
Auto Detailing at Stevenson Acura
Tree Stand
Music Loft Gift Card
Golf and Cart for 4
Beach Bowl for 6 (x2)
4 Rounds at Ten Pin Alley (x5)
Ice House Skating for 4
Shuckers Gift Card
3 Fishing Rods
Max's Pizza
Walgreens Gift Bag
Second Wind Fitness Membership
O'Leary's Car Service
Poplar Grove Gift Basket
...and more!

The drawing will be held May 29th at 5:30PM in the EV Shop.

You can purchase tickets from any EV Student.

Coupler, Battery Boxes, and Charger

The past two weeks have been very busy in the EV shop, as we are working on all three vehicles at the same time.  We still have much to do, but are on track to finish in time for the EV Challenge next month.

The coupler to mate the electric motor with the transmission has been machined by Mr. Sholar at Cape Fear Community College.  The next step is to install the motor.

The new coupler

Thank-you cake.

Also, the battery boxes and heaters are being installed in the Volkswagen.  Next, we will install the cells and wire everything up.

Bolting in the rear battery box.

Matt wiring the battery heaters.

With the Ranger, we have mounted the new charger.  It will be back on the road as soon as the controller is repaired.

Brady securing the charger.

On the road again!

The battery transplant is now complete and the MR2 is back on the road, thanks to seven long hours of work on Saturday by some dedicated students.  Re-wiring the Orion BMS took a lot of time and patience (and a call to their ever-helpful customer support line), but it is now working to equalize our new battery pack.  There are still some final details to attend to, but now our attention can shift to the Volkswagen and preparing for the EV challenge.  Check out the pictures of our progress.

Drilling out holes for the battery straps.

The front box, ready to go back in!

Moving the bug out of the way, so the MR2 can get on the lift.

Since the new cells are smaller, we need new holes for the battery cables.

The back box is almost finished...

Everything is in place up front.

Another Busy Week in the Shop

This week has been rather hectic in the shop.  We have run some cables and repaired the parking brake in the Volkswagen, and are modifying the motor, coupler and adapter plate to make everything fit.  In the MR2 we have removed the old Thunderskycell and are modifying the battery boxes to accept the smaller, yet more energy dense cells.  We will then have to do a rewire of the Battery Management System (BMS) before the car can get back on the road.

Also, we received a very generous donation this week from one of our sponsors, Atlantic Tool and Die!

David cutting apart the clutch disk to use in the coupler.

Ryan using the shop vacuum to pull cable through the heater channels.

Hunter removing the Thundersky cells from the trunk of the MR2.

Corey and Ryan working on the parking brake in the Bug.

Dillon grinding off the auxiliary output shaft on the motor so it will fit in the back of the VW.

Out with the old...

We have finally removed the old internal combustion engine from the Volkswagen Beetle!  It took much longer than it should have because we had a hidden bolt on the back side of the transmission.  Now it's time to design some battery boxes and get the conversion going.

Success!