AMP 2008 Saturn Sky EV revival x2

[RodS]

I am trying to revive two Saturn Sky’s that were original a projected joint venture between Amp motors and GM.


Below are a couple of links:

https://teslamotorsclub.com/tmc/threads ... ion.98036/
http://www.saturnfans.com/cars/sky/amp- ... onversions

I bought these two from a gentleman that lived in the Cincinnati Ohio. This is where AMP company headquarters were. They have since changed the name to the Workhorse Group. One was pretty much all together except it was in an accident with a deer I am told. It is a 2007
Saturn that was once owned by the CEO of AMP. Not sure if he was the one that hit the deer

The other one was pretty much disassembled. It was a 2008 with only 4100 miles on it and was said to have been the original prototype. It does have a tag on the dash stating it is #1 build. This is the car that I want to concentrate on in this forum group.

What I would like to do is eliminate some of the older electronics and try and integrate a Toyota Prius gen 3 inverter with the existing dual motors.
Here is a list and pictures of what came with the 2008 Sky:
Dual CMP2700XX41 Parker 37.1 kW 650vdc motors
Dual PM100DX Reinhart AC Induction Motor Controllers

Delphi Universal 2.2 km Dc Converter

Elcon TCCH-H389V Charger

55 SE-100AHA Batteries (missing 29) even though the charger shows 114 cells…. I could only see where there was room for 84 cells.

2 Matric Technology Solutions MIAC Controllers
Vehicle Power Interface module
Valence U-BMS_XP_HV Battery Management with 8 GTBMS005A_MC11 modules
Intrepid Control System
Various HV wires, boxes, fuses, and contactors


Parts that I have for updating 2008 Sky:
Gen 3 Prius inverter Logic board kit- V1
Gen 3 Prius inverter Logic board dual motor kit- V1d
24 kWh Battery pack from 2011 Think City Car EV

Since the original project has many proprietary items and there is a reluctance to share any of the information from AMP. I am planning to use repurposed items in this build.

I would like to use the Gen3 Prius inverter with the dual motor logic board to control the two motors. I have also entertained the idea of using a Prius trans-axle and completely eliminate the dual motors. I would try to re-fabricate the dual motor mount to accept the Prius trans-axle. I am definitely open to any and all suggestions on this.

[RodS]

Just a little background about myself. I am purely a hobbyist when it comes to EVs. I have a very good understanding about ice engines and classic cars. But when it comes to software I am totally lost.

I never considered EVs until my youngest son bought a Tesla. I got hooked pretty quickly! We tossed around ideas of classic car conversions and that is when I discovered the “world of Damien Maguire” Now I am really hooked! So I decided I was going to do a conversion.

In my search for possible vehicles and electric motors I found on Facebook Marketplace this gentleman looking to sell the motors and controller as a package.

I called him and he told me the story of how he acquired the 2 Saturn Sky’s and parts and I couldn’t resist, I had to buy the whole lot. I made a couple of 100 mile trips getting it all and now I’m the proud owner and I am determined to get both operational.

This all started back in august of 2020. I bought the first Prius inverter with no real direction but real enthusiasm! I ordered the first logic board from EVBMW workshop. I waited patiently for my parts to arrive. I was sure I could find someone to do the soldering for me. Guess what…..I couldn’t find any cell phone repair shops that wanted to risk the liability to do this. I thought I could find a TV repair company to do this……have you tried finding a TV repair company lately? Let alone one that does soldering! It’s a dying breed! Most seem to be merely parts replacers! No technical expertise anymore!

Even though I had always failed when I tried to do soldering, I decided to give it a try myself! After numerous YouTube lessons and watching Damien’s videos. I ordered all my soldering tools and supplies and jumped in with both left hands. I decided to start with the easier and work my way to the more challenging. I actually did pretty well until the 50 pin connector! I soldered it OK, I just soldered with the notches facing the wrong way!! Damn! Went back to my friend, YouTube, discovered Fast Chip SMD removal kit. Ordered it from amazon and within a couple of days I had removed the connector! Yea me! Of course I destroyed the 50 pin connector.

Back to the internet. Found the part number on the GitHub parts list. The only place that I could find them was Chip One Stop out of Japan. Anticipating more fails I order 10. Parts bill $12 shipping $40.

So if anyone needs one I have extras. I finally got the connector and got it soldered on properly. Tested the board and everything checks out OK!! Time to bust open the inverter.

I follow Damien’s video and get the inverter open. Get the board out and go to install the new board. The boards are different!! Well in my haste I never did enough research and my very cheap inverter was for the Prius C model which is the similar board as the Yaris.

Back to the internet and order another inverter Prius gen 3 from EBay. Well about this time Damien introduces the dual motor board. Got to have it!! So now I have it!

Now I think I have you all up to speed on where I am on my projects.

Please bear in mind….I am not a photographer……nor am I writer/blogger….or an engineer…..or a software anything!! Just an old guy that enjoys keeping busy with projects.
Thanks all for your future patience!

[mdrobnak]

Those are good controllers, not sure about that motor. Looks like some fun times ahead! Good luck with your project, and I look forward to hearing more!

-Matt

[m.art.y]

I follow Damien’s video and get the inverter open. Get the board out and go to install the new board. The boards are different!! Well in my haste I never did enough research and my very cheap inverter was for the Prius C model which is the similar board as the Yaris.

You might have made a wrong conclusion about Prius C inverter. I've seen one similar before and all was needed to do to fit V1c Prius board was to break off one of the plastic guide pins on the inverter and the board fits and all the connectors are the same.

[RodS]

Those are good controllers, not sure about that motor. Looks like some fun times ahead! Good luck with your project, and I look forward to hearing more!

-Matt

Thanks Matt! Yea I think they are good controllers and they will probably be available soon.

[RodS]

I follow Damien’s video and get the inverter open. Get the board out and go to install the new board. The boards are different!! Well in my haste I never did enough research and my very cheap inverter was for the Prius C model which is the similar board as the Yaris.

You might have made a wrong conclusion about Prius C inverter. I've seen one similar before and all was needed to do to fit V1c Prius board was to break off one of the plastic guide pins on the inverter and the board fits and all the connectors are the same.

Thanks for the heads up on this. I still have them both so I will try them out and update them on here

[Bratitude]

That duel motor set up may be superior than a Prius transaxle. You don’t have any diffs! direct reduction drive! torque vectoring ultimate traction control!

[mdrobnak]

Honestly, I'd try and get it going the way it was first - Reinhart is now Cascadia Motion, and very much is still in business. It's not going to care much about the battery stuff which seems to be your main item that needs replacing.
Might want to take a look at https://www.cascadiamotion.com/documents

-Matt

[RodS]

I follow Damien’s video and get the inverter open. Get the board out and go to install the new board. The boards are different!! Well in my haste I never did enough research and my very cheap inverter was for the Prius C model which is the similar board as the Yaris.

You might have made a wrong conclusion about Prius C inverter. I've seen one similar before and all was needed to do to fit V1c Prius board was to break off one of the plastic guide pins on the inverter and the board fits and all the connectors are the same.

Thanks for the suggestion. I did open my Prius C inverter back up and here is original board

It is smaller than the Gen 3 Prius inverter Logic board kit- V1 board and two of the connectors are swapped

I couldn't attached two of the screws on the new board but it seems pretty secure. I just wonder if I will need to fabricate a ground strip to the bottom left missing screw on the board to the inverter.

All connected up

[RodS]

That duel motor set up may be superior than a Prius transaxle. You don’t have any diffs! direct reduction drive! torque vectoring ultimate traction control!

You may be right. I was thinking that a Prius Gen3 transaxle would be lighter and take up less space in the rear of the car. Possible give more room for additional batteries. Plus I believe the Prius Gen 3 has more power than the original setup.

[RodS]

Honestly, I'd try and get it going the way it was first - Reinhart is now Cascadia Motion, and very much is still in business. It's not going to care much about the battery stuff which seems to be your main item that needs replacing.
Might want to take a look at https://www.cascadiamotion.com/documents

-Matt

Thanks Matt for this link! This may change the direction I go with this build.

I think I have the battery pack that will work. It's the 24kWH lithium-ion battery pack out of the Think City car. The battery pack was actually made by a company out of Indiana my home state! The battery pack is modular... 16 modules with 24 cells per module with built in BMS. The car that it was removed from had only 4500 miles on it. So I think its got a bit of life left in it.

[m.art.y]

I couldn't attached two of the screws on the new board but it seems pretty secure. I just wonder if I will need to fabricate a ground strip to the bottom left missing screw on the board to the inverter.

Yes not all of the screw holes align and board sits there a bit skewed but that does not matter too much. You can attach an extra ground strap just to be safe but the inverter works as is also.