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Getting 62 MPG in my revived 2003 Prius

Discussion in 'Generation 1 Prius Discussion' started by orange4boy, Apr 24, 2010.

  1. orange4boy

    orange4boy Member

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    Location:
    Vancouver BC
    Vehicle:
    2003 Prius
    Model:
    N/A
    A few aero mods, a bit of learning and little help from my friends.

    62 mpg 420 miles, 6.77 gallons and $25. That's 3.8 L/100Km for my fellow Canadians.

    Thanks to all the helpful Prius chatters. You know who you are.
     
    #1 orange4boy, Apr 24, 2010
  2. Tideland Prius

    Tideland Prius Moderator of the North
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    wow! That's Gen 2/3 territory. Congrats!
     
    #2 Tideland Prius, Apr 24, 2010
  3. orange4boy

    orange4boy Member

    Joined:
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    Location:
    Vancouver BC
    Vehicle:
    2003 Prius
    Model:
    N/A
    That's with 2 passengers, 1 22lb Jack Russel, 2 60lb deep cycle batteries and misc. luggage.

    This is how I manage it:

    Techniques:

    P&G when below 64 KPH
    Keeping to 55 mph and below without inducing major road rage. "Only in Canada you say? Pity"
    Timing lights and avoiding the brakes
    Maximizing momentum
    Safe drafting when possible
    Engaging regen with brake pulse then backing off. Seems to reduce friction brake losses.
    Shift to neutral at lights. Saves ~1 amp.

    Current Mods:

    Basjoosed hood and headlights with closed cell foam tape.
    Grille block. Internal, upper and lower.
    Engine bay / hood insulation.
    Type WS transaxle oil (to replace type IV)
    Windshield rain deflectors removed (front windshield was replaced without rain gutters)
    Low profile wipers
    Custom stainless 18" screw on mooneyes
    Front air dam
    4" Side kilts
    Traction battery pre-heater
    Front air dam
    5-20 synthetic.
    Nokian WRg2 52 psi front, 50 psi rear.
    12V system run with deep cycle batteries
    750 watt transaxle block circulation tank heater
    1500 watt engine block circulation tank heater. 70 - 90˚C Operating temp at start.

    Planned Mods:

    Regen boost circuit (autospeed article)
    Rear stainless wheel skirts
    Rear wheel boattails
    Belly pan upgrades
    Optimize front air dam transition
    Active grille block using electric antenna hack.
    Rear fastback conversion with plexi
    Basjoos door gaps with foam tape
     
    #3 orange4boy, Apr 24, 2010
    WHCSC likes this.
  4. Tideland Prius

    Tideland Prius Moderator of the North
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    holy cow that's a lot of mods.


    I ran 38/36 on Integritys on the 2005 Prius and got a 3.9L/100km tank. Shows you the advances of the Gen 2 over the Gen 1! I can't wait to see what you'd get on a Gen 2 or 3 (3.5? 3.0?)
     
    #4 Tideland Prius, Apr 24, 2010
  5. bwilson4web

    bwilson4web BMW i3 and Model 3

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    Excellent list:
    That is "~1 amp" of traction battery current or aux battery?

    I've been looking at a little simpler system based upon the accelerator automatically shifting into "N" when released and back into "D," if already in accelerator "N," for brake. Alternatively, shift to "B" to soften traction battery charging. This needs study and of course, careful testing. One thing that pops out is a smarter cruise control: (1) slacks off up grade, and (2) speeds under 23 mph (37 kph.)

    Other than Yankees tourists, is it possible to piss-off a Canadian?

    Impressive tires!

    Normal USA circuits are 15 A @120 VAC ~= 1800 W. Do you have a single, 20/30 A service plug? Or are these 220 V. heaters?

    Do you have a warm-up protocol ... say 1-4 hours before driving?

    I've been following your progress from transaxle replacement and many of the other changes. This journey would make an excellent web page, a 'how to do it.' <GRINS> So you got the car back in September and this is after 6-7 months?

    BTW, I wouldn't worry too much about going with an NHW20, not that they didn't do some good stuff and it is a larger vehicle with more space. A lot of that can be mitigated by simply removing the rear seat back and not bolting it back in. This would let you put in oversized loads.

    All in all, an excellent effort.

    Bob Wilson
     
    #5 bwilson4web, Apr 24, 2010
  6. orange4boy

    orange4boy Member

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    One amp from the traction battery as read by the Graham scanner.

    I get away with one 15A outlet. One plug for the 1500W the other for the 750W tank and the 200W battery warmer. I think they must pull a bit less than their ratings.

     
    #6 orange4boy, Apr 25, 2010
  7. adric22

    adric22 Ev and Hybrid Enthusiast

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    I bet with the addition of an Enginer plug-in kit you could reach or exceed 100 mpg.
     
    #7 adric22, Apr 27, 2010
  8. orange4boy

    orange4boy Member

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    It's on the list. Perhaps this fall. I will probably go with lead acid though. I'm not liking what I'm seeing with their BMS and the failure rate of the lithium cells. I can always upgrade later as well. Plus I already have a set of lead acid cells here for my other EVs.

    Fun fun fun.
     
    #8 orange4boy, Apr 27, 2010
  9. adric22

    adric22 Ev and Hybrid Enthusiast

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    Well, I have the Enginer kit in mine 2002 model. I only spent $1,500 on the kit and I average 74 mpg city/highway. I haven't had any trouble with the BMS but I also check on the charging periodically and if the balancers are beeping, I unplug it.
     
    #9 adric22, Apr 27, 2010
  10. vegasjetskier

    vegasjetskier New Member

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    What's the max sidewall pressure on those tires?
     
    #10 vegasjetskier, Apr 27, 2010
  11. orange4boy

    orange4boy Member

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    51 psi. max sidewall. And oops, I bunged up that entry. 52 psi front, 50 rear. Where did that 65 come from?

    Edited.

    Sweet! I'm going to hit 74mpg combined first then get the kit. I like a challenge. And I'm crazy like that.
     
    #11 orange4boy, Apr 28, 2010
    2 people like this.
  12. WHCSC

    WHCSC Member

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    I'd love to see pics of these mods.
     
    #12 WHCSC, Jun 28, 2012
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