I've been wondering about this for a while now. Asuming money was no object, could you convert a normal car into a hybrid?

In a general case, no, but I would consider two variations:

A) Efficiency enhancements such as: throttle-by-wire; converting manual to by-computer control; auto-stop. These lightweight modifications won't cost much nor require significant re-engineering.

B) Chop-shop hybrid - putting a Prius front end on a Scion xB would be a challenge but practical. This would bring the first micro-van hybrid to the states.

But in real life, money and time are important. I've bought a NHW11, 03 Prius that I am reworking into the car I want. So far, I've added a 1 KW inverter for 120 VAC; replaced transaxle oil with synthetic; replaced transaxle vent plug with a breather tube; and added XM radio. I have plans that include: variable air inlet; transaxle radiator and heater; block heater; battery heater; hybrid vehicle ECU 'wrapper'; semi-folding rear seat for large payloads; power passenger seat; exhaust heat capture; and a tow bar and utility trailer. Depending upon how some of these experiments come out, I may add a plug-in, commuting battery system and whole house UPS, 12-18 KW. Then there are some advanced EV modes and high-speed cruise improvements but my plate is already full.

Modifications to an existing hybrid, like my used 03 Prius, includes starting from a good base that you improve upon. Each change and modification is a single step so if there is a problem, you back it out. Finally, you have the advantage of other owners to identify 'low hanging fruit' and folks to ask questions about puzzles.

If I had to do it over again, I'd probably start with an 01 Prius instead of the 03 Prius. I'd have saved about $7k yet still have the base needed for all of my plans. But the 03 Prius has the advantage of residual hybrid warrantee and all of the previous engineering changes.

BTW, the same approach could be used with Honda hybrids. It just dependends upon which architecture you want to start with. There are many fine aspects to the Hondas and 'low hanging fruit.'

Bob Wilson

Operation Iraqi Oil Freedom:

Automatic, stock, project car.

My other 1500 cc car:

Automatic, stock, backup car.
Free speech, dialog and knowledge thrives without the poison of SPAM.

I have always wondered what an efficient non-hybrid car could manage with all the ancillary efficiency features that comes on the hybrids, such as ultra-light alloy wheels, low rolling resistance tires, aerodynamic body modifications, and instant mileage display, without actually being a hybrid . Those types of changes would easily be doable as well (The mileage display can be done with an aftermarket OBD-code reader and the right software), and should probably be the first things done on such an experiment.

Making a true homemade hybrid though is certainly possible. I remember reading an article about this vehicle made by high-school students in Pennsylvania. They used a 2-seater lightweight kit-car with a Jetta TurboDiesel engine powering the rear-wheels, and a 200hp electric motor powering the front wheels. Splittng the electric and engine-powered driven wheels would probably be the easiest way to do a home-made hybrid. To modify a stock car, the best way would probably be to start with a part-time 4wd car (so that it has axles for both sets of wheels), but replace the transfer case with an electric motor dedicated to the rear wheels, and let the engine be dedicated to the front wheels.

Hi Mike,

I had achieved 38 MPG with the last tank from our '91 Camry versus the regular 32 MPG. But it was by aggressive use of predictive braking and slow hill climb with 'clutch in' down hill coasting. I'd thought about making it a hybrid but the fuel tank and loss of trunk space, not to mention the control problems, made it impractical. There are limits to what can be achieved.

I liken the task to trying to convert a Sumo wrestler into a long distance runner. Better shoes, a diet and a lot of work would eventually improve the Sumo wrestler's long distance capability. But they'll never be a contender. It is much easier to performance tune an existing hybrid electric than rework a gas only car. Looking at the range of performance in the GreenHybrid database suggests this is the case.

I too admire the student's work but have concerns that other vehicular features were missed. A good first step, it would be even better if they'd fitted a Prius or Honda drive system into a kit body . . . or better yet an aircraft style frame and built a light-weight, foam and fiber glass body.

I agree that modification of a 4WD vehicle to hybrid electric would be a start by providing the wheels and transaxles. The only problem is 4WD vehicles are frequently built with a lot of extra weight. This would be a significant hurdle to achieving high MPG performance. Still, compared to a gas only vehicle, especially if attention is paid to EV modes, it could work.

Now this would be an excellent theme for either "Mythbusters" or better yet, "Junkyard Wars." Now "Junkyard Wars" already did a build for a high MPG vehicle and "Mythbusters" did the pickup 'tailgate' and 'AC vs windows' tests. Of the two, I prefer the "Junkyard Wars" approach especially if they started with gas-only cars. Then there was a car rebuild show that used to have two teams baselining identical cars and then racing them. A hybrid of these shows building a hybrid-electric would be hilarous!

Bob Wilson

Operation Iraqi Oil Freedom:

Automatic, stock, project car.

My other 1500 cc car:

Automatic, stock, backup car.
Free speech, dialog and knowledge thrives without the poison of SPAM.

I am posting this info rather late in the game, but for a few hours more there is a parts-only 2001 Prius on ebay for 99 cents.

http://cgi.ebay.com/ebaymotors/ws/eB...RK%3AMEWA%3AIT

Photos suggest that the hybrid system *might be* intact. Flatbed it from Pennsylvania to your shop and dig in.

DAS

of course if money was no object anything is possible. How many times must I post this story about the high school kids that built a biodiesel hybrid that gets 50 mpg and goes 0-60 in 4 seconds?



http://evteam.gambitdesign.com/album...0003.sized.jpg

Asking a question like this invites an answer like this:

Like Sysyphus and his rock in Hades, you are condemned to post the same story time and time again for the hubris of only one way to build a home-built hybrid. <GRINS>

Look, I hope the kids sell 'plans' for their car and make a mint. I admire their work but there is more than one way to home-build a hybrid. The essense of home-built is variety and emphasis upon what the builder believes is important.

The kids have announced some pretty impressive performance numbers but I'd be more interested in an independent EPA mileage and Dept. of Transportation evaluation. To claim 0-60 in 4 seconds and 50 mpg is a little too good to be true. Something is missing.

Bob Wilson

Operation Iraqi Oil Freedom:

Automatic, stock, project car.

My other 1500 cc car:

Automatic, stock, backup car.
Free speech, dialog and knowledge thrives without the poison of SPAM.