Membre F.F.V.E.
Identification

Electric Renault Alliance convertible - Elon Musk with his Tesla is a copycat! :)

Renault Lectric Leopard

 
Everyone has already heard of the electric Renault 5! No?

As early as 1979, the Renault 5 Lectric Leopard appeared in the United States. The most famous of the electric Renaults of that era, long before the Zoé, Tesla, and the latest electric revamps: r5, r4, twingo.
This rarity was produced by "U.S Electricar Corporation"
An ecological car before its time, it was designed for short urban trips, much like many small electric cars today. Zero polluting emissions, zero noise.
The car was powered by a 48-volt electric motor with energy sourced from 16.6-volt batteries installed under the hood and in the trunk.

It already reached the staggering speed of 50MPH or 80KMH!

Battery charging was completed overnight (115 Volt / 20 Amps) - it was possible to get a charge in 2 hours with the 230-volt option. Not bad for the time, right?
 

And then there is Chris Roberts, a passionate engineer who built a unique model!

 
Source: Chris Roberts HIMSELF! (RACP happy!)

Chris Roberts, 38, from Belleville, is an infrastructure specialist for Ameren Illinois. He works at the Collinsville office and still commutes today (early 2020) in his newly converted electric car.

Chris knows our little "RACP" site well and that makes us extremely happy :)

"It is still my daily commuter car for work and in August 2020, it will have been on the road for 7 years.
Since I've had it, it has covered 101,000 miles (162,543 km) including more than 23,000 miles (37,014 km) since its conversion."


Why a 1985 Renault Alliance convertible?
"For convenience," he answers. "I had the car. I drove it to work (in St. Louis) until 2006, when the timing belt broke. I was just able to coast into the parking lot."

It must be said that Renault Alliances have been part of the family for many years. photo 1. First, a 1983 Renault Alliance Sedan: bought new by his father (Earl). In the photo, which dates from 1986 (Chris was 11 years old), they are at a campground in the western United States (Colorado or New Mexico). A family of 4 and a lot - a lot of camping gear for a trip of over 4,000 miles, round trip, in two weeks across the United States. A grueling road trip in a very small car compared to the rest of the American auto market.

photo 2 & 3. Next, a 1986 coupe - His father was in charge of vehicle purchasing for the newspaper where he worked. He loved their Alliance sedan so much that he arranged for the company to buy some for business purposes in 1985 and 1986. When they were sold at auction in 1990, Chris bought the one that belonged to the publisher. In the photo, taken in 1993, Chris (aged 18) is repairing/replacing the idle control part with his father. It's very hot... 100 degrees Fahrenheit (37 degrees Celsius) and they had parked the car in the shade of a tree in the backyard.
He drove this car until 1998. It's his favorite car... his first.

photo 4. Finally, the 1985 Alliance Convertible. Purchased in 2001 from a "little old lady." Her husband had bought it for her but she never liked it (the car, not the husband). In 2007, following the timing belt failure, the engine suffered damage that Chris was not ready to repair. On the 1.4L, it was a chain, but on the 1.7L, a belt that could potentially break again. Chris couldn't part with the car and the idea grew to try an electric conversion. It sat in the driveway and then in the garage until 2011, when Chris finally had the time, inspiration, and money to actually start the project.

A coupe, a sedan, and a convertible. All that's missing is an Encore. "I spent two and a half years working on the electric conversion, working on it in the garage."
He bought all the components, batteries and everything, and assembled them all. You can see some of the technical details further down the page.

He had a lot of problems with this car. After replacing the timing belt that broke in St. Louis, he only had enough time to get back to Belleville before the new belt snapped. And this time, the engine was truly damaged.
"I learned that it was a known problem among mechanics," Chris said.

So he scrapped the old engine and turned to electric.

"My father, a qualified electrician, had helped me work on cars when we were both younger, and that naturally continued with the Alliance convertible. He built the circuit that supports all the original dashboard gauges."
Under the gas flap is an electrical plug, which would fit a standard 220-volt clothes dryer outlet in case of emergency.
"You only need a 100-foot extension cord," Chris jokes.

The Alliance handles the regular 24-mile (40 km) round trips to his work without issues.

He is still trying to determine the maximum mileage the car can travel on a single electric charge.
"I haven't traveled more than 25 miles (40 km) with two people so far," he said.
"I guess the maximum distance would be somewhere between 40 to 50 miles (65-80 km)."

A recharge takes about three to four hours, he said.
The car can only accommodate two passengers because some of the batteries fill the space where the back seat was. There are also batteries under the hood and in the trunk.

Chris says he spent just under $25,000 on this renovation, half of which was for the purchase of the batteries.

To find all the parts he needed, he made many trips to junkyards throughout the region.
But there were other complications: He shipped the original transmission to Arizona where a shop fabricated an adapter to work with electric power. When it came back, some of the connection bolts were too short and the only match he could find came from a DeLorean.

The gears go from one to five, but he never really could shift into fifth...
"I only went up to 65 mph (100+ km/h) once during testing," he said.

The interior of the car was also reworked. There is a new stereo and heating system. But no air conditioning.

His best estimate of the battery weight is about 360 kg (800 lbs), which makes the car a bit heavier than its original weight. He has special shocks to handle this weight, which tends to be concentrated in the rear.

"I hope that when the batteries need replacing the cost will be lower, as technology improves over time," he said. "The documentation indicates that the batteries should handle about 1,000 charges. That's about three years, but I'm hoping for four to five years."

Obtaining his license plate, specific to electric cars, "237-EL" came with a discount. But it was a real uphill battle with the administration.
"The state's incentive program for electric cars was so complicated that I opened the application, looked at it, and closed it immediately," he said.

Aside from obviously being a vintage car, the slightly faded red Renault doesn't attract much attention, Chris said.
"Most people don't notice it except in parking lots," he said.
"Once, I was at Belleville Crossing and a guy was looking at it because it's old. But he did a double-take when he noticed it made no noise."

Building a fully electric car is not for the faint of heart, he said. There are many advantages, but there are also disadvantages.
Now, Chris is subject to a new syndrome that often applies to electric car drivers.
"I feel range anxiety," he said.

 
 

Technical data

 
source : www.evalbum.com


Motor HPEVS AC-50 3-Phase AC
Drivetrain Original 5-speed JB gearbox
Controller Curtis 1238-7601
Batteries 32 GBS 200AH, 3.20 Volt, Lithium Iron Phosphate
System Voltage 96 Volts
Charger Elcon PFC-5000
Configured with charger profile 501 with no BMS.
Heater Dual 1500W Electric Heater elements. 2 cores fit perfectly in the old heater core frame
DC/DC converter Meanwell SD-1000H-12
Instrumentation Original gauges and lights being run by custom VCL in the Curtis controller. Digital ammeter is functioning off a negative side 1000A shunt in the pack circuit.
Top speed 70 MPH (112 KPH)
Downhill, of course. ~60mph seems to be the highest speed for any real length of time.
Range 52 Miles (83 Kilometers)
Still pushing the limits on this slowly.
EV miles Start:77,672 Miles (124,974 Kilometers)
Current:81,254 Miles (130,737 Kilometers)
Total:3,582 Miles (5,763 Kilometers)
Seating capacity 2 adults
Tires Bridgestone B381 85T
Conversion time 2.5 years
Additional features Upgraded suspension. The original Alliance suspension is not up to the job of holding that much battery weight. KYB aftermarket shocks with a set of MAD Suspension Coilovers with custom seats restore a reasonable ride height to the rear of the car.

 
 

for those who want to rebuild a flux capacitor

 
- Wiring junction layout
- EV Wiring Diagram
 
 

Six years later.

After six years, here is an update on Chris's project. The Renault Alliance Club is delighted to hear that the Alliance is still on the road.

"In early 2022 I returned home to charge the car after one of these outings and found that the Elcon on-board charger had stopped working. With the GBS batteries also due for a refresh I had to decide if it was time to retire the car, or, keep it and implement some improvements. In the almost 10 years between 2022 and when I first drove the "converted" car in 2013, EV technology had made giant steps forward thanks to countries and manufacturers worldwide. I had also come to regret some of my original design decisions, which I could now have the opportunity go back and correct.

I decided to refit the convertible, but limited the major changes to the storage/charging system. Tesla battery modules, then and now, provide one of the best energy/weight ratios and those became my first choice for replacement storage. 5 of Tesla's 22.5V modules provide not only a higher voltage than the original GBS cells but also weigh almost 1/3 less. All 5 Tesla modules could now fit in the same limited space that only 5 of the GBS cell bundles occupied behind the front seats too! I was fortunate to find AmpREVOLT (https://amprevolt.com/), a company in Lancaster, PA USA, which provides an almost turn-key Tesla based storage and charging solution. From a modular battery box to hold the Tesla modules all the way to the new Elcon charger, I was able to single source the upgrade parts for about $12,500 USD.

And while the trunk was now full of the components required to manage and cool the new batteries, I had room up front, without a battery above the motor, to move the Curtis controller to a better position. In my original conversion I tried to avoid introducing new liquid sources, thinking "electricity and liquid don't get along". This led to finding out that the Curtis 1238 series controllers just can't approach their maximum operating limits for any length of time with passive cooling alone. In most hot summer weather it was impossible to travel even 10 miles without the controller throwing the overtemp alarm and cutting power. Repositioning the controller allowed me to add a chiller plate and cooling loop to better control its temperature.

Finally, there was work that had to be done to marry all the old technology to the new. Newer Orion and Elcon components communicate best over CANBus protocol but it wasn't really feasible to try to tie the older Curtis controller into that communication channel. Orion's BMS system does provide some analog level outputs for interconnection, but they are tied to the car's native 12V system. The Curtis' inputs are all tied to its own internally generated 12V supply, so a new set of opto-isolated circuits had to be built to bridge that gap. There were also programming changes to the Curtis VCL application I custom wrote which had to be made in order to tie in the signals from the new BMS.

Not needing the convertible for commuting, I was taking my time with making all these changes. Then, in April of 2023, my company (like many others) decided to force employees back into the office. Fortunately for me it was only 3 days a week. By September I had the car back on the road and use it regularly to drive to work again except during the most extreme hot or cold days. There are just over 104,000 miles on the odometer now. About 3,000 miles more than when we last spoke and almost all since the upgrades were done.

Attached are some new pictures, here are some descriptions to go with them for you:
  • BattBox0.jpg - This is the modular AmpREVOLT Tesla battery box configured to hold 5 modules. One Tesla 85-Type module is inserted.
  • BattBox1.jpg - This is the busbar end of the fully loaded and wired battery box.
  • BattBox2.jpg - This is the liquid cooling end of the battery box.
  • BattBox3.jpg - Using an engine hoist to lift the fully assembled battery box into position in the former backseat area of the convertible.
  • BattBox4.jpg - The rear face of the installed battery box showing the power connections (left-hand side) and cooling connections (right-hand side) all attached.
  • BattBox5.jpg - The front face of the installed battery box. I painted the aluminum face black to match the top/side panels as well as the car's carpet.
  • Trunk.jpg - This is a similar view to photo 6/12 of the original article you have on the site already. All of the new storage/charging components are in the trunk area which used to hold 2 GBS 200AH cell sets and the Elcon PFC charger. Clockwise from top center, the components on the center plates are: Cooling radiator and fan, Tesla cooling pump, AC-DC converter (leeches power from J1772 charging port), Elcon "HK" series charger, Orion WiFi Connect module, rear fuse block, Orion BMS 2 module, Orion Thermistor Expansion Module.
  • EngineCompartment.jpg - This is a similar view to photo 5/12 of the original article. Dead center of the image is the Curtis controller in its new location with the new interface box with the bridge circuits in it (the prominent LED readouts show the a variable 5V reading passed between the Orion and Curtis systems which is translated within a 5% tolerance)

Once again, a big thank you to Chris for all the information, the photos, and the time he dedicated to writing this email. It was a real pleasure to read!
Your story is truly incredible, even if I’m not sure I understand everything.
I hope our readers will appreciate your work just as much as we did at the Renault Alliance Club!
The only electric Renault Alliance in the world :). Incredible!

Chris Roberts
Belleville, IL (USA)
email on request. "
 
 

A very timid start

In 2020, things were starting to move in France regarding Retrofitting. But Covid gave a serious blow to the growth of this great idea. Today, development is very limited due to delays, costs, and homologation.
Many pioneers went bankrupt. Neither supply nor demand is meeting expectations.
Yet...
 
 
 
 

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