Brian's Website > Car Projects > Toyota MR2 EV >

EV Project Timeline

This is a combination "TODO" list and summary timeline of the milestones in my Toyota MR2 EV conversion project. As I make progress I am replacing TODO's with completion milestones. See also the EV Project Expenses.

  • October-November 2006: Research Phase. Determined I want Toyota MR2 or Honda CRX / Civic Hatch, completed EV Performance Analysis based on those chassis selections and anticipated battery and motor selections. See EV Reference Material section for a compiliation links to some of the useful information I found out there on the net.
  • November-December 2006: Search for Honda CRX, Civic Hatch, or Toyota MR2.
  • December 21, 2006: Purchase 1985 Toyota MR2 for $400. Bad engine and a few minor dents, but overall solid.
  • January 2007: Strip car of unneeded components. See the EV Weight Change Page for details.
  • Feb 2007: Transmission overhaul and modification.
  • Feb 21, 2007: Transmission internal modifications complete. Fidanza aluminum flywheel on order. See MR2 EV Transmission Modification page.
  • Feb 28, 2007: Fidanza flywheel arrived. Ring gear removed. New Pressure plate and clutch disk (stock) acquired.
  • March 3, 2007: Scrounge section of 2" pipe and a chunk of old conveyor belt for raw materials to make new transmission and motor mounts.
  • March 7, 2007: Complete modifications to front and rear transmission mounts by removing old "dogbone" rubber mounts and attach much stiffer solid Custom Motor Mounts made from pipe and conveyor belt.
  • March 8, 2007: slightly used Advanced DC 9" motor on order. Adapter plate to fit motor to transmission on order.
  • March 16, 2007: Motor And Adapter Plate delivered! Motor needs mild cleanup and paint job. Adapter plate (unfortunately) needs some reworking, but at least the supplier acknowledged this and gave me a discount.
  • March 25, 2007: Adapter plate hub repaired. Thanks go to my Uncle Frank. See Motor And Adapter Plate page for details.
  • April 3, 2007: Passenger side (back-of-motor) motor mount designed. Frame bracket tacked in place.
  • April 1, 2007: Batch of 16 trojan T-105 batteries purchased for nearly nothing. Not exactly what I want, but useful anyway. See EV Battery Considerations for more details. These batteries have the same physical dimensions as the final battery type I want.
  • April 8, 2007: Rear battery rack layout identified. Will hold 10 batteries. See EV Battery Racks page for details.
  • April 24, 2007: Rear battery rack deck and chassis mounting brackets completed. See EV Battery Racks page for details.
  • April 30, 2007: Engine compartment Chassis Modifications complete. Compartment cleaned, painted with urethane-based truck bed liner. Ready for final installation of rear battery rack and EV Motor and Transmission
  • May 6, 2007: Motor and Transmission final assembly completed. Motor painted. Rear Motor mount finally done. See Motor And Adapter Plate page.
  • May 13, 2007: Motor and Transmission installed into car. Rear EV Battery Racks installed.
  • May 16, 2007: Begin work on front compartment Chassis Modifications.
  • June 4, 2007: Front end Chassis Modifications done, compartment painted with truck bed liner. Front EV Battery Racks done and installed.
  • June 11, 2007: Exterior body work done, all dents repaired and primered. Interior stripped for repairs, cleaning, and access to wiring.
  • June 20, 2007: 12v wiring harnesses that I hacked up while stripping the car has been repaired. Unneeded circuits removed, Old engine bay fuse block relocated to front compartment. See EV Electronics page for more details.
  • June 24, 2007: All parts needed for brake and clutch hydraulic repairs on order. See EV Project Expenditures page.

  • June 25, 2007: All major EV Components either in hand, or on order. Controller, Charger, Vacuum pump should be arriving within a week or two. Contactors and DC-to-DC converter on hand. See EV Electronics page for more details, and See EV Project Expenses page too.
  • July 8, 2007: Built defrost heater out of a toaster. Installed into original heater core location. MR2 Dashboard mostly reassembled. See EV Electronics page for details.
  • July 14, 2007: All Major EV Components in place on the car: Controller, Charger, DC-DC converter, Vacuum Pump, Main and Reversing Contactor. See EV Electronics for more details. Everything still needs to be wired up.
  • july 16, 2007: Interior cleaned (aggressively) and largely reassembled. Remaining trim pieces waiting to be installed dependenent on finishing wiring
  • July 18, 2007: New Tokico high-performance shock absorbers on hand. Customized springs on order from Gitt's Spring of Auburn, WA. Struts off the car and ready to be rebuilt. See my EV Suspension page for more details.
  • July 30, 2007: First smoke test of largely-complete EV Electronics 12v system. Happily, no smoke escaped; only had one crossed wire. All automotive functions, EV Braking System vacuum pump ckt, Main contactor ckt, Reversing ckt, DC-DC converter contactor, safety interlocks all working. Still TODO: In-dash stuff: switches, buttons, indicators, gauges for EV related components.
  • August 7, 2007: Charger, boost transformer, plug-in port, and 12-volt charger interlock power supply installed and smoke tested.
  • August 14, 2007: Dashboard wiring: EV Gauges, Reversing buttons, Reverse indicator, charging indicator and ventilation fan, heater controls all finished. All 12-volt EV Electronics are done and tested.
  • August 17, 2007: Began making and installing battery and motor cables.
  • August 18, 2007: EV Suspension System upgrade completed: heavier springs to carry the battery weight, and a one inch lowering to improve handling and reduce aerodynamic drag.
  • August 19, 2007: Finished reassembling braking and clutch systems.
  • August 24, 2007: Insured the car. Current tabs good until the end of October 2007, long enough to go down to the emissions inspection place and get the title updated to electric propulsion. That should be interesting.
  • August 26, 2007: High-voltage EV Traction Circuit completed (except for battery interconnects which don't go in until after batteries do)
  • August 31, 2007: Battery tie-down brackets done.
  • September 4th, 2007: Installed Batteries and interconnect cables.
  • September 4th, 2007: First Successful Test drive

At this point, the car should be running... All further todos are enhancements to running vehicle!!!

  • September 7th, 2007: Bought set of seventeen brand-new Trojan T-105 batteries. Due to lax research on availablility of T-875 batteries with terminal type I need, unable to install that type of battery without redoing all my cabling and waiting 3 months for special order batteries to be made. Doh!
  • October 15, 2007: Bought a set of 1991 Honda CRX 5Jx14 alloy wheels. These are the narrowest 14" alloy wheels you can get near as I can figure and they are compatible with the MR2. The wheels are 1/2" narrower wheels than stock with a slightly deeper offset and smoother face.
  • October 22, 2007: Fabricated and installed a lightweight interior rear bulkhead cover to replace the very heavy stock carpet. Made plastic trim panel for center console around circuit breaker.
  • November 2, 2007: Replaced transmission fluid with 10w30 full synthetic oil. This should improve transmission efficiency slightly.
  • Late 2007: Got a new set of four Bridgestone B381 low rolling-resistance tires, and mounted them on 1991 honda CRX 5Jx14 alloys. The Bridgestone B381 is among the best low rolling resistance tires you can get.
  • Early 2008: added spreaders springs to rear disk brakes, same as what the front has. (significant difference in drag noted between front and back brakes after reassembly, but need to re-check after break-in period)
  • May 2008: Maaco supreme paint job and some bodywork done. Paint isn't perfect (hey, its Maaco, you get what you pay for) but it is much improved over the primer and peeling paint before.
  • TODO: Make rear fender cowlings to improve aerodynamics.
  • .