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EV Weight Change

This page was originally written before the car was finished, but I can tell you now what the final result is: The car weighs 3140 pounds dry. (no passengers, cargo, or gas!) Read on for more details.

This page provides a quick analysis of where the weight change in my Toyota MR2 EV conversion came from. There are three basic categories: Removal, Modification, and Installation. In all tables, positive numbers indicate weight removal, negative indicate weight gain. Numbers preceded with ~ are approximate. Note that this was enough of an increase in weight to exceed the original GVW of the vehicle, requiring that I upgrade the EV Suspension System.

Toyota MR2 recyclable take-off parts
Toyota MR2 recyclable take-off parts
Toyota MR2 removed fluff
Toyota MR2 removed fluff
Toyota MR2 unneeded parts to be given away or sold
Toyota MR2 unneeded parts to be given away or sold
Toyota MR2 original engine.
Toyota MR2 original engine.

The above pictures are of most of the stuff removed from the car that is unnecessary as an EV. Some materials that I removed I am keeping to re-task for other purposes in the car, but that consists of less than 5% of the total material removed. In the above pictures, the material is sorted into three categories:

  • Recyclable metal: Tubing, brackets, the exhaust system and some A/C components that are not worth selling or keeping.
  • Fluff: Plastic, rubber hoses, insulation, trim material and other useless, non-recyclable garbage.
  • Usable components: Parts removed from the car that I don't need but will try to sell or give away to avoid junking them. The engine, cooling system components, gas tank, and a lot of other odds and ends fall in this category.

Weight Removal

DateComponentsWeight (Lbs)
Dec 28Spoiler, Mudflaps, trunk interior trim20
Dec 31Engine Compartment miscellaneous peripherials25
Jan 1Radiator, cooling fans, A/C condenser, some A/C plumbing33
Jan 14Exhaust System, Gas Tank (weight figured includes 10 gallons of gas), Alternator, more A/C plumbing151
Jan 19Coolant plumbing, A/C compressor, more engine compartment junk.46
Jan 20Engine OUT! Weight minus flywheel/clutch assy which get re-used243
Jan 27Intergal battery tray -- grind it out1
jan 28Heater core and A/C evaporator10
sept 4Engine cooling fan and cowl, misc parts held back for possible reuse that didn't happen25
TOTAL WEIGHT REMOVED554

Modifications

DateComponentsWeight (Lbs)
February 2007Substitute Fidanza racing aluminum flywheel with ring gear removed. This is a huge inertial weight savings.7.5
February 2007Transmission modification. (really done for reduced friction, not weight reasons) Remove fifth gear and reverse internal components.5
May 2007Chassis Modifications -- front compartent expansion -- removed unneeded brackets and radiator support4

Installations

DateComponentsWeight (Lbs)
April 2007Motor + adaptor-150
April 2007Rear battery Rack-25
April 2007Front battery Racks-25
August 2007Electronics-150
Sept 200717 Batteries (Trojan T-105)-1050
TOTAL WEIGHT ADDED1400

So, if the car lost about 550 lbs of weight, and gained about 1400 lbs, then the net weight change is about 850lbs. This means that if the original curb weight of the car is 2250 lbs, then the car weights 3100lbs as an EV. (Update: Car weighs in at 3140lbs according to the scales at the local dump).