last updated June 13, 2009

Ok, this is the part that matters most: cost
I'm trying to keep everything as cheap as possible without sacrificing quality and safety, which is quite the challenge.

Time:
Even though I've been researching as early as February 2008, I'll start the clock at the day I received my truck. (though work didn't start until a few days later)
August 24, 2008 -...
I'm going to finish the clock on the day I finished a 54.5km test run. (though I've done test drives much earlier than this date) June 12, 2009. This project has taken waay too long, and will probably never reach 100%. I'm sure there will always be something that could be tweaked, replaced, or improved.

Money spent so far (all prices include tax and shipping if applicable)

ADC FB1 4001A Electric Motor $2060.10 including shipping and taxes (from CANEV)
- shipped to my friend's workplace with a truck loading dock
(would have been $1750USD [$1925CAN] from EVA, but importing taxes/duties/fees were unknown - GST alone would be nearly $100)
** I know it would have been much cheaper to use a forklift motor or similar previously used materials, but I want this truck to be highway capable, plus I want a motor that I can take out of this chassis and keep for future conversions. (so I wanted a NEW one.)

From GrassrootsEV
(all prices include shipping - and I'm shipping to an address in NY to save some $)
144V Logisystems Controller $1369.45 CAN ($1250 USD) - update: I received the 72-120V version, while this means I can get the truck moving sooner, it is the WRONG CONTROLLER!! >:( I paid for the 144V version. See my controller page for more info. Apparently I could have gotten a better controller from EVcraft for 800$, I didn't learn about this until it was waaay too late however. oh well, now I know for next time.
Throttle POT $93.19 ($85USD)

From EVSource
Anderson Connector
500amp relay (LEV200A) ** I damaged this one and I may have to buy another. (update: I fixed it using a compressor to remove the air that got in, and sealing it with vacuum tubing and JB-Weld)
total including shipping $122.83 CAD ($109.55 US) (shipped to my contact in NY)

Another Anderson connector (ebay) (including shipping)
$26.69 CAD ($20.94 USD)

repair manual for 89 Ford ranger (from ebay - includes shipping)
$12.89 CAD ($11.81 USD )

Electric Vacuum Pump (for diesel engines) (from ebay - includes shipping)
$95.61 CAD ($88.79 USD) more info here

engine hoist rental (4 hrs)
32.77 CAD (29.89 USD)

Vacuum Reservoir - with ABS pipes from Home depot.
about 30$ CAD (27.36 USD) (inc cement, hose and adapters)

Parts for drive shaft coupler
failed weld-together sprocket about $20CAD (18.80USD)
replacement sprocket $34.55CAD (32.49USD) including shipping from this surplus website
aluminum spacer bar, and sheet metal - about $23CAD (20$USD) (from Canadian Tire)
M5 - 8.8 grade hex bolts, nuts, washers, locktite $25CAD (22$USD) (from Home Hardware)

Transmission adapter plate (total $50CAD (42.05USD), not including tools)
16"x16"x1/2"Steel plate was $30CAD no tax! (from sheet metal supplier)
Bolts and washers were about $20 (from Home Hardware)
tools: $64 (Teg's Tools)

Motor mounts
$9CAD (7.57USD) in steel for bracket. Used existing mounts and bolts from original engine.
(I think the quality of my work on this part was really crappy and I may have to re-do it, but for now it seems to be working fine. no pictures because it is so dang ugly.)

SHAWMUT A3T400 400A fuse. (from ebay) $27.34CAD 23.00 USD
According to the manufacture's website (page 39 of this document) this fuse is rated for up to 160VDC.
It is important to know the difference between AC and DC ratings of fuses. I've done my homework here.

Giant Green start button - $5.65CAD (4.75USD)(from sayal surplus electronics, - drove to Burlington)
I've decided the way to go for starting the car is with a button + ignition key. Turning the key to run will enable the button (lights up) (and enable pre-charge resistor), pressing the button will close the contactor, (light turns off). Turning the key to off will release the contactor! I've already put together a test circuit for this and it works! More details (and video) posted on the misc page.

Amp meter $51.93CAD (42.63USD)
I'm going to try a different route than what other EVers do. I've ordered an HTB 200, a solid state current transducer that can measure up to 500Amps (DC or AC). This will be connected to a cheap 5$ 3V analog meter I got from sayal electronics. Got a digital volt meter off ebay for 8.99US to replace the analog one. I didn't know they could be found that cheap. More info here

Volt meter/battery monitor - $148.91CAD (125.23USD)
I've taken this idea from a fellow Canadian - forkenswift.
using an LM3914, (from digikey) and a LED display (100LEDs so far) from Sayal, I'm putting together a compact, nifty little gauge that will tell me all I need to know. The cost of this went up quickly, but it is way more effective that a single meter across the whole pack, and cheaper than the "proper" way of battery monitoring with the paktrakr
I had to buy fuses, in-line fuse holders, LEDs, PCB, LEDs, and a few other discretes. If it cost any more, I'd only have to console myself with the price that the paktrakr would have cost me: $219.90USD plus shipping. ($261.39CAD)
More info on the battery monitor here.

Conductive Carbon Grease - From Sayal $14.63CAD (12.30USD)
this will be used for most of the wiring connections, mainly the high voltage crimping points.

Misc small parts (spade connectors, aluminum bar for battery buss, grinding discs, tachometer hub)
about $23CAD (18.34)

IOTA DLS55 DC-DC converter $145.79CAD (115.00USD) from ebay
This is actually a 120V AC to 13.8VDC adapter, but according to this website, it will work with a DC input. I'll open it up and connect the inputs on the rectified side of the rectifier to maximize the benefit. more info here

Crimping tool/bolt cutter- $14.67 CAD (11.37 USD)
made from 18" bolt cutter (see misc page for more info)

Cable lugs - $31.41 CAD (24.34USD)
bag of 20 from Appleby Marine (found via ebay)

2/0AWG welding cable - $145.43CAD (112.70USD)
30" from Princess Auto at 4.29$/foot - this recently became a regular stock item, so I can get more when I need it

split poly loom 3/4" $15.49CAD (15.56USD) for a 50 foot spool
for protecting welding cable. I got this from Sayal electronics surplus.

Ceramic Heater - xmas gift! - info on installation here

Quick-Charge brand 144V 10A charger. This is simple, lighter than 12 individual chargers, and easy to plug in anywhere. It also has a built in charge curve for whatever lead acid batteries I use.
From chargingchargers.com $574.49CAD (477.05US) including US domestic shipping, no tax.

Additional Fuses and fuse holders
18.31CAD (about 14USD)

Steel and other materials for battery frames: 183.58 (from various hardware stores)

heater controls 33.32 (USD)(sayal) (built 2 heater relays, both failed)
heater relay (from EV source) 48.45CAD (39.88USD)

more cable lugs: 28.02 (USD)(too many actually)

Battery balancers $68.90 (parts from Digikey and sayal)

Conversion Total: (update: April 5 2009, I'm creating a separate total since conversion quotes usually don't include the donor vehicle or the cost of batteries)
$5556.38CAD (around 4814.40USD) as of June 12

Total investment:

Truck: $650 + UVIP, plates and tax ($136) = $796 (aprox $739.24 USD)
(I was fortunate enough to find a truck that was already safety certified and emission tested, so I to put plates on it while the papers were still valid)

Batteries: $271.20CAD (about 208USD) for 4 wet cells (got these to add to my free batteries, but then I found 12 AGMs for $720CAN (636USD)

Parts for Battery Management system (charge balancing): 22.20 for fuses and resistors from sayal, and 48.23 for mosfets and other parts from digikey, totaling $70.43

Battery Chargers and modifications: $493.60CAD (385.92USD -January exchange rate)
11 Battery chargers from Princess Auto (on sale at 29.99each) $ 338.89 CAD
Parts for modifications: 85.82 CAD (that's only 8.50 per charger!) More info on my chargers here
***Note I will try and sell these chargers since I replaced them with a proper single unit, but until I sell/return them, I will include the price here.

$7907.61 CAD

I have to admit that 5k might be a bit too tight of a budget, especially with Canadian currency, I had also hoped to rely completely on free batteries, but that didn't work out. I never would get a nice range if I did that.