Prototype 1:      

Original Prototype 1

Updated Prototype 1



Prototype 1 is a recycled Harley Davidson-AMF electric golf cart that will be used for systems implementation and refinement.  Below are some pictures of Prototype 1, click on the pictures to enlarge:

 

The first step for Prototype 1 was removing the rear of the cart for mounting a Kubota 3 cylinder diesel motor. The design for an engine mount, most of the metal and mounts were recycled to keep costs down.  The rubber mount is a Nissan 240sx transmission mount.
  
 The Kubota motor in its new mount; this will be a test engine for the biodiesel that will eventually run in Prototype 2.  The motor will be coupled with a generator head and a small turbo will also be installed.   Starting the 3 Cylinder D600 Kubota motor; formerly the motor did its duty as the power plant for a lawn tractor.  The motor will serve out the rest of its life as a test mule for the project.
  
 The motor is running on automatic transmission fluid (all that was available at the time) which shows how versatile a diesel motor can be.  Team Desert Fuel wants to power their vehicles with the cleanest most environmentally friendly fuel possible.  A renewable fuel like biodiesel is the most positive move to make for a truely green car.  

With the diesel motor running, Prototype 1 underwent a face lift and systems integration, below are pictures of the systems installed, the restoration efforts, and the strides made towards a series hybrid vehicle.  Click on the pictures to enlarge:

   
 Custom mount and tensioning screw for the 10 kW generator.

Kubota motor mounted on Prototype 1 with a belt coupling on the 10 kW generator. 

Foot rest and battery compartment prior to reconditioning. 
  
 Foot rest prior to reconditioning. Battery bay prior to reconditioning. Foot rest with restored panels and protective paint.
   
 Stripping down the battery compartment. Prepped for stripping down to bare metal. Battery bay reinforcements for structural stability. 
   
 Restored battery bay.Restored foot rest. Battery bay and foot rest restored. 
   
 Installation of canopy and windshield. Mounting for gas tank and rear wind deflector.  Installation for mounting of rear wind deflector.  
   
 Prototype 1 has a fresh coat of paint!Testing of solar panel and battery charge controller.  Prototype 1 with dual solar panels, solar panel controller, generator, diesel motor, monitoring systems, iGo charger, and battery charge controller. 

   
 Temperature controlled biodiesel tank. Wiring diagram for batteries and monitoring system.Connecting monitoring system. 
   
Y connection for biodiesel or diesel. Solar panel controller and power monitoring. Monitoring switch matrix for time division multiplexing. 

   
Turbo plumbed and temperature monitored.Monitoring system level efficiencies.   Prep for baseline system efficiency tests.
   
 Testing biodiesel system level efficiencies. Monitoring system temperatures.