3KW EV Conversion - Plug In Supply

Hello all!
Recently I started work on the conversion of my Prius C to a full plug-in EV. Since purchasing my C this year, I've been fixated (maybe obsessed?) with getting great MPGs, so I've made some changes right away such as overinflating the tires, and blocking the lower grill. Over the months I've learned to master the pulse and glide, and even the warp-stealth (where appropriate), bringing my 12 mile work communte to a gas-stingy average of 64MPG.

But this isn't enough, especially when what I really wanted was something more like the Leaf or the Volt, but of course they didn't make sense economically. So I decided early on to go with an aftermarket conversion and after some research decided that Plug-in Supply seemed to have the best system. I thought I'd post some pictures as I do the conversion for anyone that's interested.

The hardest issue so far was getting the HV cable to tie into the factory pack. You have remove the back seats and completely unblot the factory pack to slide it forward enough to do the install. Having gone through it this part is clearly the hardest issue with doing this conversion, but it's just a matter of undoing all the right bolts and knowing where you're going.

The attached picture is what I got with my KIT so far from Plug-In Supply. I am going with the controller installation first, then purchasing the battery cells and boards for a 3KW system at a later time due to my crappy finances.

 

Here are some more pictures of what I've done on the installation. There's no space under the driver's seat on the Prius C, but fortunately, the front and rear controllers both fit perfectly under the passenger seat.

I appriciated finding velcro already attached under the controllers, which I could use to stick to the carpet, so there was no need for a tie-strap or anything else to secure it. From the front controller there is a cable which needs to run into the diagnostic port. I was able to hide this completely by running it behind the dash, then cramming it between the dash and the center structure behind the change pocket, then underneath the plastic of the center structure to get under the seat. I was surprised I didn't have to remove anything to completely hide this cable.

Also shown is the 12VDC cable which needed to be attached to the positive end of the 12V battery and the negative discharge point on the car's frame.

There are a couple of connections I still need to run, but it's mostly installed and waiting for a battery now which I hopefully will be putting together myself later this month.

 

Hi Rockmills,
Well it all came down to economics. Currently, I'm trying to get rid of debt and my first plan was to a car I bought for 2k thinking of how much I'd save, but ended up paying an additional 3k for repairs in 4 months, and would have needed much more to pass a smog test so I abandoned that idea. So I wanted car with payments under 300 that would equal even lower payments due to fuel savings. At the time I looked at it I think the Prius-plug in was 36k, and I could get the C for 22k. I couldn't see myself paying that sort of premium for the paltry plug-in range of the current model, when the point of this was to see how much I can actually save. If they stuck a big battery and charged 25k I would have been all over it but they are holding the market back on purpose as part of a long-term strategy (in my opinion).
So anyway, the Prius C conversion was the logical solution.

 

From what I understand there is an a EV switch that will completely disable the ICE (maybe it spins with air going through it assisted by the pumped up amperage from the battery?) and can run on electrical power up to a high speed, which I think is going to be 72mph (not sure) where Toyota has set the limit when the pack is "completely full" and the gas engine is disabled. As to whether this is safe, I'd say so since you can achive this just running out of gas and gunning it with a full factory pack on a flat highway. Also I recall they used to set this limit to 52mph, but the electric engine in the C anyway is rated for 10,000RPM and that seems reflected now in the higher limit.

 

Strongbad,
The aftermarket battery and the factory pack work together. Essencially with the extra battery continiously keeping the factory pack at 100% charge. Also, the C isn't on their website because I am one of the first trying this, I had to call and drive to San Fransisco to test my car and make sure that the software is compatible. Fortunately, it appears that the C has the exact same software as the Gen III Prius.
Dellrio,
The "EV" switch I was refering to is not the standard EV button, but a switch on the front controller which I think I'll be connecting to one of the fuses to disable the gas engine. Accourding to Plug-In Supply this allows for true high-speed EV.

 

Hi Mik1 that's something, but some of that may be old news and you'll excuse me if I don't read it. I can afford to be this flippant (no offense, you are wise to bring this up I think) because I have met the owner and was fortunate enough to test drive his system when I had him test the compatibility of the Prius C. I test drove at least 10 miles and although I used some small gass, the MPG gauge never went below 99.9MPG. With the added PEP of the completely full battery, I could easily have used no gas for the same trip if I remained below 42MPH. I must have been propelling myself with scam hot air that whole time.

The one thing that wasn't tested (and only because I didn't have time and said we didn't have to), is whether the kill switch for true EV can be used, and whether you can achive high speed by doing this. This post got me thinking I should test it so at lunch I charged up the factory battery, then pulled the EFI Main fuse. This cut the gas engine but I DO NOT RECOMMEND IT because you check a check engine light that won't go away. Fortunately, the controller board clears this sort of error and it did go away again after starting/restarting the controller board and car, but without this equipment if you try it you'll have to have TOYOTA clear it for you.

So anyway I pulled this plug, and was able to drive in all electric! (no gas even if you press all the way) and noticed immediately that there was far less cap on the RPMs of the electric motor. I only had a short road to test where I work, so was only able to get to 48MPH before stopping, but that's higher than 42. My guess is that with a full battery, given how high you can spin the RPMs of the electric motor in this mode, with a 3KW battery, I should be able to hit high 68 or so MPHs on a flat highway, but I'll have to wait till I'm finished to find out for sure.

 

Thanks Ryephile, and sorry guys I just want to keep it positive for some reason if you can understand that. My wife gave me a hard enough time when I used up all our money for this exclaiming how it will actually save us money. I only made this thread because the reality appears that this thing will turn out amazing for my car and thought it could be useful.
I didn't even notice but I used my real name this forum when I signed up and did not intend to. So anyway, yes I'm a real person I'll keep working on it when I get time will update this thread.