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Thread: Project 1 from ShaneJackson. Category: Custom Automotive on/off road Welding

  1. #1

    Default Project 1 from ShaneJackson. Category: Custom Automotive on/off road Welding

    Looks like I am the first to post their project for the new winter time contest.

    This is a fun one. I am building a custom roof for a 6 seat NEV car..... AKA a limo golf cart.

    The original fiberglass roof will be removed and 8 - 60watt solar panels will be added. The plan is to add an inverter so the cart can be used as a solar generator in a power out situation. I may also add a small grid tied inverter so any excess power can be feed back to the grid.....

    The original roof was held on with 1" square tubing so I will be building another frame out of 1" square tubing to match.

    I picked up the metal at lunch today and will be cutting it this afternoon.... pic's coming soon.
    Everlast PowerTig 200DX
    Everlast Supercut 50P
    I need a MIG.... which one to buy:
    I-Mig 160, I-Mig 200, or a MTS 160

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    Looks like technology has come a long way in the last few months. I thought 500 watt grid-tie micro-inverters were still in the couple hundred dollar range, but it looks like they can be had for 100-200 bucks. Out of curiousity, were you planning on getting this approved by your electric company as a true grid tie system, or just plugging it in knowing that you'll never make enough power to raise any eyebrows?

  3. #3

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    Actually this is not for myself. It is for my father.... After looking at the price of the inverters, I will probably skip the grid tied portion and just have an off grid inverter.

    As for getting approval... I have checked into what all is involved as I am working on a 5.28kw system for my house.... and I can say it is a load of BULLCRAP what all is involved. Not so much the permitting, application fee's, and all the paperwork they require.... but the "contract" they require (and the super low rates they pay for the power you produce) and the monthly fees they charge just for the privilege to hook up and feed them power.... I say screw them! I'm going off grid.
    Everlast PowerTig 200DX
    Everlast Supercut 50P
    I need a MIG.... which one to buy:
    I-Mig 160, I-Mig 200, or a MTS 160

  4. #4

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    Interested in the grid-tie for cheap too. Far as a gold cart. Last few I did where 6 seats. What brand? Aluminum 1x1 I assume?

    Not big on battery golf carts (all mine are gas powered), but the grid-tie is another direction.
    Mike R.
    Email: admineverlast@everlastwelders.com
    www.everlastgenerators.com
    www.everlastwelders.com
    877-755-9353 x203
    M-F 12 - 7PM PST
    FYI: PP50, PP80, IMIG-200, IMIG-250P, 210EXT and 255EXT.

  5. #5

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    Nope steel 1x1x 16awg. Aluminum would have been better (lighter) but cost too much.

    The car(t) is a Star 48-6L
    Everlast PowerTig 200DX
    Everlast Supercut 50P
    I need a MIG.... which one to buy:
    I-Mig 160, I-Mig 200, or a MTS 160

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    I was looking into doing a 1.8Kw system for my house and may still do it when I get my tax return next year. What power company do you use? I know SoCal Edison has applications and inspections and all that crap, but I haven't read anything about a contract or fees for hooking up solar. If you "rent" the solar from one of the company's then yeah you have to sign the 20 year contract and pay the monthly fees, but I was planning on buying a system wholesale online and installing it myself. I was just gonna pay a certified electrician to do the final wiring.
    Poewr I-Mig 205P
    Powertig 185

  7. #7

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    Duke power in North Carolina. Here is a PDF with all their fee's and such.

    http://www.duke-energy.com/pdfs/NCPPN.pdf

    One thing to note is our kWh rate is approx $.097.....

    The main thing that gets me is they charge $16.20 in addition to all other standard meter charges to have it hooked up. That's 167kW a month I would have to feed back to break even. I'm doing a tracker so I get 6.2hr a day rated power so that is about 1kW of the system just to break even with "fee's"... and that is best case. Also the chart is set up so the rates in the months of off peak (the time of the year where you may actually produce more than you use).... you get screwed royally.

    Anyways I am planning on just going off grid with all outlets, lighting, and well. That leaves the stove, dryer, and HVAC on the grid (for now). It will be a fair amount of wiring work to make the change but not a big deal for me. I wired my house when I built it 2 years ago. There has only been small changes to the code since then.
    Everlast PowerTig 200DX
    Everlast Supercut 50P
    I need a MIG.... which one to buy:
    I-Mig 160, I-Mig 200, or a MTS 160

  8. #8
    Join Date
    May 2012
    Location
    Disneyland
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    2,661

    Default

    Quote Originally Posted by ShaneJackson View Post
    Duke power in North Carolina. Here is a PDF with all their fee's and such.

    http://www.duke-energy.com/pdfs/NCPPN.pdf

    One thing to note is our kWh rate is approx $.097.....

    The main thing that gets me is they charge $16.20 in addition to all other standard meter charges to have it hooked up. That's 167kW a month I would have to feed back to break even. I'm doing a tracker so I get 6.2hr a day rated power so that is about 1kW of the system just to break even with "fee's"... and that is best case. Also the chart is set up so the rates in the months of off peak (the time of the year where you may actually produce more than you use).... you get screwed royally.

    Anyways I am planning on just going off grid with all outlets, lighting, and well. That leaves the stove, dryer, and HVAC on the grid (for now). It will be a fair amount of wiring work to make the change but not a big deal for me. I wired my house when I built it 2 years ago. There has only been small changes to the code since then.
    Stove, dryer, HVAC, and welders.

    So just your 240 stuff will need to be moved to it's own panel. Should be a pretty easy job.
    Long arc, short arc, heliarc and in-the-dark!

  9. #9
    Join Date
    Apr 2012
    Location
    Washington State
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    722

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    Quote Originally Posted by Rambozo View Post
    Stove, dryer, HVAC, and welders.

    So just your 240 stuff will need to be moved to it's own panel. Should be a pretty easy job.
    Yeah, as soon as I read stove, dryer and HVAC in Shane's post it hit me that he forgot "welders" too .... LOL!
    Is it OK to want to break something just so that you can weld it back together?

    Everlast PowerTIG 185 Micro IGBT AC/DC Welder

  10. #10
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    Well I'm sure he could run his little 140ST off his solar/inverter system, but probably not the plasma or the 200DX.
    Long arc, short arc, heliarc and in-the-dark!

  11. #11

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    Quote Originally Posted by Rambozo View Post
    Stove, dryer, HVAC, and welders.

    So just your 240 stuff will need to be moved to it's own panel. Should be a pretty easy job.
    Don't be cracking on welders...

    My welders is nothing compared to the stove, dryer, hot water heater and HVAC.

    On a side note, with power savings the more it's on, the more you have to save.

    Even a light bulb on 24/7/365 is worth looking at. But the one in the frig is not worth the time.

    And payback is the key, that drops about 95% of my projects.
    Mike R.
    Email: admineverlast@everlastwelders.com
    www.everlastgenerators.com
    www.everlastwelders.com
    877-755-9353 x203
    M-F 12 - 7PM PST
    FYI: PP50, PP80, IMIG-200, IMIG-250P, 210EXT and 255EXT.

  12. #12

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    Quote Originally Posted by Rambozo View Post
    Well I'm sure he could run his little 140ST off his solar/inverter system, but probably not the plasma or the 200DX.
    It will probably run, for a bit anyway
    Mike R.
    Email: admineverlast@everlastwelders.com
    www.everlastgenerators.com
    www.everlastwelders.com
    877-755-9353 x203
    M-F 12 - 7PM PST
    FYI: PP50, PP80, IMIG-200, IMIG-250P, 210EXT and 255EXT.

  13. #13

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    Jezz... it was almost 1 am when I posted it.... I forgot my compressor too.

    Actually my inverter is a 6kW continuous 12kW peak inverter 240v. It's a XW6048 if anyone wants to look it up. I could cut everything else off and run my 200DX. Not something I would want to do but I could if had too.
    Everlast PowerTig 200DX
    Everlast Supercut 50P
    I need a MIG.... which one to buy:
    I-Mig 160, I-Mig 200, or a MTS 160

  14. #14

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    In reply to the hassle of selling power to the utility company, A good friend of mine has setup several wind power systems here in Eastern Kansas as the wind does blow a lot. Here at our home is an ideal place as we are on top of a high area here and can see 26 miles to the west and 38 to the east. We were talking about a system here which would supplement our home but it was not cost effective and the payout would take approx 25 years if you did not have any high unexpected maintenance cost. Our annual electric cost for our home is approx $1920.00 per year for a ranch home that is 3800 sq ft main floor . A 15 year payout plus maintenance just did not look cost effective.

    He remarked about a system north of here by Leavenworth that cost approx $33,000 to install 4 years ago and the amount of return they are getting from the power company and what there power cost are now.
    His comment was that if the power company would actually pay a decent rate for the power they get he could see a profit from this but at the current rate and with maintenance costs he is not seeing his system payout
    and recover his cost.
    PowerTig 200DX
    Supercut 50P
    PowerTig Micro 185 SOLD GREAT MACHINE
    Millermatic 200
    Miller Thunderbolt
    Jet 1340 Lathe
    Jet 20" Drill Press
    Jet 12" Wet Band Saw
    Kalamazoo H7 Bandsaw
    Forward 12,000 lb 4 Post Lift

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    Here is SoCal the excess power is sold back at the generation rate, which is like $0.04/kwhr. I think the reatil price to purchase it for your home is between 0.12 and 0.27, not including delivery fees, which about double the bill. Still, the system I was looking to purchase was a 1.8Kw system and had a payback time of ~8 year. The system was going to be $8900 to purchase, ~500 in permitting fees, and between $500-1000 for the electrition to do the final wiring after I physically install the system myself. Federal tax credit of 30% knocks $3000 off the price, and Edison is paying ~$0.14/watt in incentives, so another $250. That brings my total cost to ~$6800 and will save us ~70 bucks a month. Works out to 8 years break even, but we also just installed a pool and don't know how much the pump is going to run a month, so it may be less time until payback. I live in the middle of the desert, but used a 5 hour a day estimate as my roofline is east/west.

    After that Edison just bills you once a year, so you don't get screwed every month with generation rates. If you produce more in the winter than you use, you save the credits until the summertime when you can use them up. Only once a year do they tally up used vs produced and send you a bill. So as long as you don't install a system that generations huge amounts of overages, then you don't really get screwed on the production vs retail rate.
    Poewr I-Mig 205P
    Powertig 185

  16. #16

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    If you are serious about a system, wait for one of my next projects.... It is a solar tracker. I have the same problem with not much good south facing roof line so I am doing pole mount. Originally I was just going to do a fixed system but figured out a way to make them a single axis tracker for around $200 more.
    Everlast PowerTig 200DX
    Everlast Supercut 50P
    I need a MIG.... which one to buy:
    I-Mig 160, I-Mig 200, or a MTS 160

  17. #17
    Join Date
    Apr 2012
    Location
    Washington State
    Posts
    722

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    Quote Originally Posted by ShaneJackson View Post
    If you are serious about a system, wait for one of my next projects.... It is a solar tracker. I have the same problem with not much good south facing roof line so I am doing pole mount. Originally I was just going to do a fixed system but figured out a way to make them a single axis tracker for around $200 more.
    A solar tracker would be a cool project. I'm curious what kind of hardware you will use to implement this. I'm completely green (no pun intended!) about this solar stuff so who knows, there's probably a dozen off-the-shelf or DIY products out there already to help you with it.
    Is it OK to want to break something just so that you can weld it back together?

    Everlast PowerTIG 185 Micro IGBT AC/DC Welder

  18. Default

    I looked into doing the tracker but don't have the space for it. I'm on a 5500 sq. ft. lot and to not break any local laws about panel height above the roofline and other stuff the only thing I can do is about 3" standoffs and a flush mount on the roof.
    Poewr I-Mig 205P
    Powertig 185

  19. #19
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    Quote Originally Posted by agent4573 View Post
    I looked into doing the tracker but don't have the space for it. I'm on a 5500 sq. ft. lot and to not break any local laws about panel height above the roofline and other stuff the only thing I can do is about 3" standoffs and a flush mount on the roof.
    You could always make the house a tracker.

    Long arc, short arc, heliarc and in-the-dark!

  20. Default

    That is absolutely insane.
    Poewr I-Mig 205P
    Powertig 185

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