Baker forklift + Suzuki Swift + Geo Metro = Project ForkenSwiftProject ForkenSwift - Electric car conversion on a beer budget

GE EV-1 control panel

< prev. photo
(Click image for larger view.)
next photo >

GE EV-1 control panel

Here's the brains of the forklift.

This control panel includes all the circuitry, fuses and contactors (big relays) to turn the two hydraulic pump motors on & off, as well as the power steering pump motor, plus various contactors for safety and change the direction of the drive motor.

Several of those contactors are in use in the car.

At the top right of the panel is the GE EV-1 motor controller for the main traction motor we originally thought we would use in the car.

View all ForkenSwift galleries > DC motor controller ...

Curtis 1204-412 motor controller
That green box is the controller that's in the car now: a rebuilt Curtis 36-48 volt 400 amp DC motor controller original...
GE EV-1 control panel
Here's the brains of the forklift.

This control panel includes all the circuitry, fuses and contactors (big relays)...
GE EV-1 DC motor controller
The EV-1 SCR (silicon controlled resistance) type of controller actually has decent features: including adjustable accel...
The GE EV-1 controller on the "test bench"
We knew that the EV-1 worked: we had dropped 3 marine batteries in the Baker forklift and moved it under its own power f...
GE EV-1 controller in action (light test)
For testing, instead of controlling a DC motor, the EV-1 was hooked up to one of the 36 volt spotlights from the forklif...
Curtis 1204-410 36-48 volt 225 amp Club Car golf cart controller
Even after getting the EV-1 to work, we decided a "plug and play" golf cart controller would be easier for testing/devel...
Finned aluminum heat sink
(Inset: controller mounted on the heatsink)

Controllers can get pretty hot when they're worked hard or for a long tim...
Precharge resistor
Most controllers have banks of capacitors inside that help to smooth current flow. The capacitors gradually discharge w...
Curtis 1204-412: adjustable features
Note the adjustable current limiting (CL) and acceleration rate (ACC). Plug braking (PLUG) mode isn't used.

For maxi...
plug graphic  

bullet Home

bullet How fast? How far? How much?

bullet EV parts list

bullet Videos

bullet Conversion journal

bullet The used forklift

bullet Conversion cost

bullet Thanks/credits

Hansler Industries
Hansler Industries, Brockville - thanks!

(menu below not yet functional)


lessons learned


ev resources



  • Nissan's smallest global car is the Micra. More info & discussion at the new Nissan Micra forum.

  • Mitsubishi Mirage forum / owners club: info & discussion about the Mirage (plus Space Star, Attrage and G4).