Last update: May 25 2016
12 Volt Power
Batteries
Cabin Heat
Charging
Controller
Engine Wiring
Fuel Tank Removal
Fuel Gauge
Mods and Upgrades
Motor
Motor Adapter
Odds and Ends
Power Brakes
Power Cabling
Power Steering
Suspension
Tachometer
Temperature Gauge
Wiring
| Motor | 11in DC, makes about 160hp |
| Battery pack | 16kWh Lithium |
| Drive train | Stock AWD transmission with clutch |
| Curb weight | Near stock. 50/50 weight distribution |
| Range | 40mi |
| Charge time | 7 miles range per hour charging |
| Efficiency | 88 MPGe (77 city / 99 hwy) |
| Instrumentation | JLD404 |
| Cost | Car $10K + Conversion $15K = $25K |
| Fun factor | 110% |
Most everything in the car works like it did before the conversion, except there is no air condition or cruise control. The car has a short range and I originally intended to add more cells after I had the car working. A few months of use changed my mind. Forty miles is plenty for me. I routinely drive this car 60mi in a day, charging between trips.
Performance is good and driving the car is fun. I generally start off in third gear. The car takes off and pulls nicely all the way until 40mph, when I shift to fourth. Second gear works well for parking maneuvers but is too jerky for road starts. The overall power feels quite respectable although it is less than the 2.5L turbocharged engine. It is difficult to compare an electric motor with a gas engine. The noise of revving a gas engine greatly impacts your senses, and the torque curves are very different. The Subaru driveline has a lot of lash and flex, which leads to a harmonic surging effect on takeoff. To counter this, I hold the brake with my left foot for a moment while applying the throttle, to take up the slack.
There are all sorts of subtle sounds to hear such as the tires and drive line. When accelerating briskly, the Soliton1 controller goes into performance mode and whines. When stopped at a quiet location, you can just hear the hum of the motor cooling blower. Turning the ignition on or off makes all kinds of loud clicks from all the new relays.
The power steering and power brakes work smoothly and feel just like before the conversion. Traction balance front-to-rear seems unaffected by the major change in weight distribution. The car neither understeers nor oversteers.
Here is an instruction card I made up for occasions when I leave the car at the body shop after a fender bender, or such.
Some considerations for converting an EJ Subaru:
| 20 Sep 2015 | Fuel gauge operating based on distance
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| 18 Aug 2015 | Replaced the used power steering pump with a brand new pump |
| 2 Jul 2015 | Motor cooling blower delay module
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| 30 May 2015 | Controller ready status by check engine light
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| 20 May 2015 | Replaced one bad cell
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| 20 May 2015 | Reprogrammed charger status indicator
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| 3 May 2015 | Upgraded powertrain mounts
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| 17 Apr 2015 | Cell measurements indicate BMS not needed
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| 12 Apr 2015 | Second trunk exhaust fan
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| 6 Apr 2015 | Inlet cap
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| 20 Mar 2015 | Charge warning light module redesign
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| 8 Mar 2015 | Fuel door label
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| 24 Jan 2015 | Replaced failed solid state relay with Gigavac P105
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| 4 Jan 2015 | Cabin heater connected
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| 30 Dec 2014 | Controller status indicator
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| 30 Dec 2014 | 12V system voltage display
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| 26 Dec 2014 | WRX pedals
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| 27 Nov 2014 | Fog lights as daytime running lights
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| 23 Nov 2014 | Added module to control charge warning light
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| 8 Nov 2014 | Badges repainted & overlayed
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| 9 Oct 2014 | Charger status LED relayed up to package shelf
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| 5 Oct 2014 | Recovered seats
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| 6 Sep 2014 | Ventilation fan rids trunk of heat from charger
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| 16 Aug 2014 | Showed at the West Coast Subaru Show. Received Best Swap and People's Choice awards |
| 7 Aug 2014 | JLD404 battery meter installed
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| 4 Aug 2014 | Tachometer working
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| 9 Jul 2014 | Motor temperature gauge complete
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| 3 Jul 2014 | Added two additional straps to top of main battery box
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| 25 Jun 2014 | Wireless access to controller
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| 22 Jun 2014 | Cabin heater switch connected
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| 18 Jun 2014 | Front ride height adjusted
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| 8 Jun 2014 | Replaced some lamps with LEDs
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| 6 Jun 2014 | Rear ride height adjusted
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| 31 May 2014 | Sealed between battery box and body |
| 24 May 2014 | Shortened aux shaft
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| 24 May 2014 | Motor blower PWM speed controller
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| 23 May 2014 | Added side spoilers
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| 10 May 2014 | 12V battery charging monitor installed
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| 4 May 2014 | Second DC-DC installed
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| 26 Mar 2014 | Controller liquid cooling functional. Performance is noticeably better
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| 18 Mar 2014 | Installed scoopless hood
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| 14 Mar 2014 | Upper battery pack insulation panels
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| 9 Mar 2014 | Installed motor blower speed control power resistor |
| 8 Mar 2014 | Installed controller radiator
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| 4 Mar 2014 | Connected ZEVA Fuel Gauge Driver. Appears incompatible with Subaru fuel gauge |
| 2 Mar 2014 | First road test. No problems |
| 23 Feb 2014 | Battery straps installed
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| 16 Feb 2014 | Charger energized, power steering pump tested |
| 2 Feb 2014 | Controller programmed
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| 20 Jan 2014 | Rework mounting for 12V battery and DC-DC
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| 4 Jan 2014 | Switch from Hella UP28 to UP30 vacuum pump
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| 28 Dec 2013 | Aux 12V wiring harness installed
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| 13 Dec 2013 | Aux fuse box mounted
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| 16 Nov 2013 | Batteries bottom balanced
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| 14 Nov 2013 | Vacuum pump reinstalled, relay moved to aux fuse box |
| 17 Oct 2013 | Power cable installed
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| 16 Jun 2013 | Vacuum pump, switch and relay mounted and connected |
| 15 Jun 2013 | Moved shunt to engine bay |
| 13 Jun 2013 | Charging inlet power wires connected
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| 6 Jun 2013 | Custom power steering hoses installed. Motor cooling blower installed
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| 2 Jun 2013 | High voltage fuse and shunt mounted |
| 20 May 2013 | Power steering fluid drained and lines removed |
| 13 May 2013 | DC-DC converter mounted |
| 2 May 2013 | Charger mounted
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| 27 Apr 2013 | Steering pump and vacuum pump mounted
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| 24 Apr 2013 | Motor mount complete
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| 16 Apr 2013 | Mounting for controller and steering pump fabricated
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| 10 Mar 2013 | Motor bolted to transmission. Working on motor mount
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| 3 Mar 2013 | Lower battery box installed
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| 21 Feb 2013 | Starting over on upper battery rack design to orient cells upright and locate charger |
| 29 Jan 2013 | Motor adapter complete
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| 21 Jan 2013 | Trunk floor removed
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| 1 Jan 2013 | Upper battery box complete
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| 18 Dec 2012 | Got flywheel from machinist. Needs rework |
| 5 Nov 2012 | Main battery box fabricated
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| 16 Oct 2012 | Motor adapter housing completed
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| 20 Sep 2012 | Batteries delivered
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| 16 Sep 2012 | Charging inlet installed
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| 29 Aug 2012 | Motor adapter redesign in progress |
| 23 Jun 2012 | A/C wiring worked out |
| 10 Jun 2012 | VSS and instrument panel grounded
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| 2 Jun 2012 | A/C pulley designed |
| 23 May 2012 | Adapter housing design finished |
| 7 May 2012 | ECU removed |
| 6 May 2012 | H49 brushes removed, H60 brushes installed |
| 4 May 2012 | Electric heater core installed
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| 4 May 2012 | Motor blower shroud complete
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| 13 Apr 2012 | Adapter hub finished |
| 12 Apr 2012 | Fuel tank and exhaust removed
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| 5 Apr 2012 | Engine removed |
