Another type of electric vehicle conversion uses an electric crate motor. It will be trimmed to length when the rear battery box (and its cable) is installed. Maybe a strange question to ask, but there is some context. This is the final part of the series on his first conversion. We've tried other pups, some in series, etc, trying to get the coolant flow up to par. The water-out comes from the coolant connection nearest the positive-mostcells, one of which has the stock Tesla temperature sensor. A bit of non-EV conversion effort is occasional restoration work. Having open space below it feels roomy. One phone call later we were on our way up north. This isroutine and is getting worked out. In this case, we narrowed it down toone of the smaller HPEVS brushless AC motors or one of the NetGain brushless SRPM AC HyPer9 motors. Classic cars deserve to live on for many more generations, and electrification is the way to do that. T5 T6 Slim LWB Kits; PRO KITS; T2 BAY; Ford Custom; Traffic Vivaro Primstar; Larger Vans; Sprinter & VW Crafter; Kitchen Pods; . Add To Boot. Thankfully, the problem appeared to be something in the wiring of the other I/O harness. Solutions like this are often a gamble, but it worked great. The box side-cover has slots intended for plumbing to exit, but those slots don't line up well with the P100D fitting locations. These images show how we are attaching the high voltage junction/fuser/contactor box (and all other parts mounted to the rear firewall of the Beetle. coolant connectors for the Tesla P100D battery modules, were included in the shipment. Can you see it? . Another shot shows the blue paint on the otherwise black rubber engine bay seal. We are verifying fit, final wire routing, and service access before the final installation of the battery modules into the box. Alas, it seems that may not be the case the era of the Beetle still has time to ride out and the funky little car has made yet another grand comeback! The testerpictured checks for proper pin-out and voltages at all connections. No. The great thing about an 818 kit is that they start at around $10k, so (without work) between the kit and the electric vehicle conversion kit youre looking at around $20k for a small electric sports car., The Karmann Ghia is a classic Volkswagen sports car that was made from the 50s to the 70s. VW T6.1 and T5 Campervan VW T25 Campervan VW T2 Campervan VW Kombi Day Van VW Split Screen Campervan VW Type 2 charging system, VW camper van ignition system, VW T2 starter motors, VW Transporter lighting and more with free delivery from Heritage Parts Centre. The wiring diagram was updated to consolidate low voltage fuses and reduce wire runs between sections of the car. The stereo and final dash replacement piece have arrived. This diagram isn't very legible in this article, but it provides an idea of how we've laid outcomponents to showlocations and wire routing over different sections of the car. Removing this took two pounds off. Thankfully one tube was supplied with the car that we could use to verify dimensions. We went with a 3kW off-the-shelf heater/fan unit neatly tucked under the firewall in the center. Volkswagen has teamed up with specialist firm eClassics based in Germany to provide the official conversion kit. We want to avoid issues in the years to come. The tires are mounted on the new wheels with chrome valve stems and caps. The coolant lines sweep down around the side and underneath the battery box to twoaluminumblock manifolds. Sourcing duct hoses of the proper size and adapting at couplers where needed was the challenge. Thirty minutes later all 10 lines for the front box were pressed onto the Tesla P100D modules. If we were to do the process again today with the same spec, the project would cost around 45,000 including the cost of the camper van. You can pick one of these up from as low as $8k., Between the Super Beetle and the Beetle, because of their mass production you can find one for relatively cheap. New Flywheel assembly, a KEP Stage II pressure plate, and a four puck clutch on a lightened flywheel - plus starter ring gear removed. With the removal of the rear-mounted petrol engine, theres the bonus of a usable amount of boot space. It probably doesn't help that the steel of this car experienced a front-end collision and may have tweaked geometry. The power delivery is 170 lbs/ft or 240 Nm of instant torque, and 130hp or 100kW. VWCRAFTER DESIGNS. Please slide to verify. The holes for the DC-DC (on the front battery box) were tapped for assembly. The battery cables in the car were cut to length and lugs crimped on. We specialise in VW camper vans because we know how they work, and more importantly, know what components fit where! This can easily cost an additional $2,000 - $3,000 on the low end for 2WD vans, and roughly double that for 4WD Syncros. You can find one of these from $10-15k., The SW20 MR2 is an awesome JDM candidate for an ev conversion. Something went wrong while submitting the form. Instead of door locks, the Type 20 uses facial . Both of these pumps have garden-hose-like flow, but we need higher pressure. But this stage is not drive testing, yet. That's the point. As part of our electric vehicle conversion service at Jack's Garage, we are very proud to be in partnership and to be the sole UK agent for the illustrious eClassics in Stuttgart Germany. How Do You Charge An Electric Car At Home? 1969 VW T2 Campervan electric conversion using a full 75 kW Tesla battery pack and Tesla Drive Unit. Based in Ghaziabad, Rexnamo Electro offers retrofitted electric cars and conversion kits for the last ten years. A couple of months ago I introduced you to a UK company that converts classic cars to electric propulsion. have been removed. What sets this apart is its range. Our mechanic was based in a small village near Whitby and found a VW specialist in Sunderland, a few miles north. . The stock yellow "Generator Light"becomes a system "Power Limit" warning light". The wiring cleaned up nicely as well. We thought wed run a few petrol campers for a while to feel out the market, then slowly convert them to electric. From this, the CAD models were updated as shown in the bottom image, and the final stainless steel parts are being laser-cut as I write this update. Many VW Bugs have been converted in the past with efficiency claims between 200 and 300 Watt-hour per mile (Wh/mi). The SW20 MR2 is an awesome JDM candidate for an ev conversion. The average cost of conversion is $30,000-$34,000 and takes about three months. The difficulty of the conversion depends on the car you choose, the power you aim to have, and the range that you want. Disappointing, but a part of the journey. A second pump (different type) wasn't good enough either. As long as healthy modules are purchased, they're a good value at around $230/kWh on today's market. Theoretically with enough time and money you can convert any car to electric, however, some cars may be much easier than others. Price: $8,734.00 Add to Cart Details The van was perfect, a perfect shell with nothing in it. You've come to the heart of the question, really. . All photos courtesy of Kit Lacey, eDub Services. There, theyll swap out the internal-combustion engine and replace it with a battery and electric motor a nice zero-emission drivetrain suitable for a sustainable future. Add to that all the ongoing costs and repair costs and the money was gone. The final known bit of wiring (coolant pump, radiator fans) was completed. The stock spring works, but not with enough safe margin. Now, back to the road trip and my mums response. That battery pack consumes a lot of space where other conversions have had room for luxuries like a heater. We are already working together to prepare the platform for the Bus. Some purists may call you a heretic for considering a conversion on this car. This is normal at this stage. So the decision was made to find a van! He visited eDub HQ and fitted the new motor and controller. The stereo amp, speakers, and other parts arrived soon after ordering with exception of the stereo itself that should arrive any day. While Chris was installing the cell tap wiring of the assembled front box, he discovered the torn cell tap circuit. Not to mention going over budget. It rode very smooth, even on the worst of downtown Albany roads. After a debug phase, the harness will all be covered by the same black wrap that is barely visible covering a 6-inch wire bundle that exits the right side of the power distribution box. Space was made under the hood to mount the charger by re-aligning the right front brake line. We also decided the 12V fuse panel will be relocated so that its backside wire connections can be accessible in the future for serviceability. The 356 is a special Porshce. I always find important decisions like this are best decided over a local Yorkshire pint! This complete kit will deliver 90 miles safe driving distance, and will charge to full in a little under 8 hours. Complete EV HypE conversion kit for air-cooled VW - High Voltage Max 90 kWatt-180 VDC 7,820.00 - 30,290.00 Excl. Feedback ID A final assembly of parts in the motor compartment is underway. Intelligent Living Media believes that information should be freely available to all, but we also believe that sources should be properly credited and that intellectual property rights should be respected. Otherwise the same external dimensions. With target battery capacity understood, we evaluate weight total and distribution, location, crush zone safety, etc. Green Hydrogen Project Is New Worlds Biggest, Utility-Scale Wind, Solar PV, & Concentrating Solar Power (CSP) Increased From 467 MW In 2013 To 6,230 MW In 2022 In South Africa, Fervo Energy Plans Direct Air Capture Facility Powered By Geothermal Heat & Electricity, 2023 Global Energy Trends: Crisis, Contingencies, & Climate Change (Video Included! Early campers were iconic. 19691979. Four concept vans, a rebadged Dodge Grand Caravan, and an emissions scandal later, VW has finally revealed the reborn electric Bus, the 2024 Volkswagen ID Buzz. Choosing a model that has been converted before can save time and avoid unseen complications. The front battery box is mechanically assembled and external wiring has begun. A lot of time went into exploring how to add a simple and reliable electric heat source while also being able to plumb the air to the existing vents. This article was created to allow the customer to follow the high-level build activity. A hoist at James' workshop holds a Land Rover Defender ready for its new electric heart; there's a pair of electrified VW Kombis, a Beetle with battery pack housed under its bonnet, and a second-generation Mazda MX-5 with the same 88kW HyPer 9 motor found in James' company demonstrator Beetle. Three days later, my mum sent me the picture on the right. turbo Garrett Mitsubishi KKK Borgwarner ihi tous modles vhicules, turbo dCi, HDi, TDi, CDi, JTD, au meilleurs prix web Spcialiste du turbo en neuf ou change-standard, kit They'll need to be traced and decide what to do with them later. With a growing interest among enthusiasts manufacturers are slowly beginning to create turn key solutions for electric vehicle conversions. First, some quick specs on the more common engines: Vanagon Engine Conversion Specs : Common . The proper heater box arrived, and of course, it's not black (a must). Maybe this is what caught my interest as a conversion. Before cutting and assembling the coolant line to the new connectors, the minimum lengths from each module to its coolant manifold must be understood. Racing is the soul of the auto industry. Complete Bay Window alternator conversion kits, voltage regulators, Volkswagen campervan split charge relays (for big stereo systems and other high-drain electrical accessories) and . Years Experience. The ElectrAA Show was also a chance to meet Robert Llewellyn, the Fully Charged presenter and a bit of an EV icon. Today was the first test drive. I've updated theP100D module coolant connector pagewith further details discovered this week. I have an old Volvo 240 in my garage that one day will need an electric drivetrain for sure, so getting acquainted with someone like Kit is a good bet. Rather than wait for a tool, I looked up some clever ways people have accomplished similar press-fits like this. It had the windows removed, and in the back, it had a bit of yellow/green interior seating (no thanks). Bothlarge lines will be routed in parallel back to the pump and radiators. P100D Coolant connections and routing to manifolds. You may want to catch up with part 1,part 2, part 3, part 4, & part 5 before I hand it over to Kit Lacey in this very last chapter of his first, and most painful, build, in which he refuses to give up on the adorable T2 Indie. It all started with a road trip. We found no leaks but discovered this pump won't work with these modules. The AC electric car conversion kit costs about a thousand dollars more than the DC, so not a lot of difference there. We launched eDub Conversions in 2019 to carry out this mission. A couple of hours later I was printing the orange parts in the image that are nested into a standard caulk gun. It's browned because it must be heated to about 400F to expand and slip onto the motor shaft. The busy upper leftimage shows cell tap and thermistor wiring connected and shims (white) that precisely position and stabilize each of the 5 modules. We can accomplish our drive systems maximum and minimum voltage range, With 5 modules wired in series, the full and empty voltages fall within the operating range of our motor controller. We're now routing wires from front to rear for 12V power, CAN1, and CAN2 communications, plus BMS and charger signal wires. VW Bus Bay Window T2 Power Window Regulator Conversion Kit Left & Right 68-79 Brand New $255.50 Save up to 15% when you buy more Buy It Now Free shipping Sponsored VW TYPE3 Fastback Variant Notchback 1967-1973 Weber Conversion Kit see details (For: Volkswagen) Brand New $619.79 Buy It Now Free 4 day shipping Last one 9 watchers Sponsored It will look a bit like we're going backward for a few days, but the new finish plan will be much better. And isnt it a good job he did! We purchase electric vehicle conversion kits from EV West. The unit is supplied fully assembled, you just bolt the unit in and follow the wiring instructions. Rather than add in-line fuses, we're adding one or twosmall fuse blocks in the engine compartment. Taking off in 2nd or 3rd gear without clutching is just as we hoped. Front box in place. The year is 2013. And the company sells a ready-to-fit . SHOP. Quantity. With t the tightest allowable radius at about 5" or 6" they need to exit near the connections on each module. The USA-740-Radio from Custom Autosound arrived. Part Number: EPAS7479. While the schematic has been complete for some time, we've started planning and routing the physical layout of wiring for the J1772 inlet connections to the charger, DC-DC, installed and wired the "charging" status indicator, CAN port connections, contactors, etc. So, back to the camper. Click here to view more details about the P100D 6.3kWh coolant connectors. That's 2kWh more than we'll need. The defrost air flow at the windscreen is impressive. All of its connectors extend to the drivers' side for easy access. The motor controller is programmed, up and running! That kind of momentum cant just come to a sudden halt. This complete kit will deliver 140km safe driving distance, and will charge to full in a little under 8 hours. Copyright 2023 CleanTechnica. It suited us nicely but we never imagined we could ever own one. We were back on track and we werent giving up! Choose your VW conversion. In addition to service work, he also began making parts by hand. I decided to buck up my ideas. Conversion Kit Price: $7,598 Volkswagen Super Beetle 1971 - 1979 Between the Super Beetle and the Beetle, because of their mass production you can find one for relatively cheap. The BMS harness has been wired to use these sensors so that itwill report what is likely to be the warmest cell temperatures. This week we began executing the plumbing strategy. Now, here lay our issue: The motor and controller were manufactured by two different companies in the US, and both had failed. In accessing and using www.intelligentliving.co and related sites, you agree that you may not download content except for personal, non-commercial reference. If you like what we do and want to support us, please chip in a bit monthly via, 70%, 80%, 99.9%, 100% Renewables Study Central, Clean tech and sustainability market research, Climate Change Solutions: Why 1.5C Is So Important, Electric Vehicle Sales Charts, Graphs, & Stats, Engage Global Competition: Technology for a Sustainable Future. We budgeted 30,000 ($37,000) and planned a 100 mile (161 km) range conversion. The power delivery is about 110 pounds of instant torque, and is a lot of fun to drive. Shipping calculated at checkout. Next, the faulting BMS unit was moved to the I/O harness of the non-faulting BMS, and it worked as expected. Shifting while moving is easy if you want to. There's no reason why we can't convert every single VW T2, is there! What followed was an amazing summer. Find the right electric car conversion kit for your electric vehicle conversion project. Don't let anyone tell you a new VW Beetle dash installation is easy. Under the hood, the top image shows the stereo amplifier laying where the battery box bottom will be. Theres no reason why we cant convert every single VW T2, is there!(?) Externally, only the coolant plumbing is a little different. The UK auto market saw plugin electric vehicles (EVs) take 20.0% share of new sales in January, flat from 20.4% year on year. This was a super short work week for me and the crew, so there's not much visually to show. Copyright 2023 EV West Privacy Notice |Conditions of Use. I've been working on various ways we plumb in a great (3kW+) heater and defrost system. Like many, it was a dream of ownership but the concern for issues also kept my cash in my wallet. Price: $8,734.00 Add to Cart Details Volkswagen VW Thing EV Conversion Kit, AC Motor, Regen Braking, 1968-1980 The EV West VW Thing Starter Kit is perfect for th . The 912 is another good candidate, and if youre into Porsche this may be on the cheaper end of what you can get. As we commit to more part locations & circuit routes, I've ordered a lot of small parts like plumbing fittings, relays, sealed High Voltage (HV) box, fuse blocks, etc. We must find the solution that we'll install so we can check for leaks in the rear module (and front) before they go in. Yes Or No? Inside the box, an aluminum plate is cut and drilled to accept two contactors, a high-voltage fuse for the rear pack, a high-voltage relay at the top, and our positive high-current battery input cables (not routed here yet). Living in the Byron Shire and running two successful businesses based on VW Kombis, he's regarded as one of the 'Kombi Kings' of the region. You can pick one of these up from as low as $8k. If that is feasible, we reviewavailable motor and controller/inverter solutions that can providethe efficiency and powerwithin budget for this application. The garage agreed to paint the van and do a left- to right-hand drive conversion for a reduced rate. Why Arent Energy Flows Diagrams Used More To Inform Decarbonization? To use all 10, we'll run two strings of 5 modules this way, in parallel. Type 2/T25 - Full-width VW Campervan Rock n Roll Bed. The rear battery box is powder coated and in position without batteries. Then the motor assembly slid forward over the transmission shaft and stoped against the adapter plate. 10 cm more height in the foot area compared to conventional sleeping roofs. So, for me, a camper van would be perfect, but which one? They started with a 1995 Vanagon and stripped the motor. The stainless panels, radiators, throttle input, BMS, motor, and motor controller are all assembled with stainless steel fasteners. Retro fit, electronic, speed-sensitive, power-assisted steering system to fit for Late Baywindow vans made from 1974 - 79. Designed for electric vehicles in the 3000 to 4800 pound range, this a true highway-capable EV kit with excellent performance! The lower-right image also shows a rectangular 3D printed cover that we designed to block the hole from the relocated fuse block. The cell taps and thermistors for the front battery box modules are wired. The HV pack fuses first. Another hole will go through the upper firewall panel above it. It was a bit of work to trim out the old gas tube and weld in the backing plate deep enough for the inlet to not block the original fuel door. With most of those parts missing, we're updating to an electric windshield washer fluid pump and reservoir. It is time to get registration, license plates, and registration! The power delivery is about 173 pounds of instant torque, and its top speed is 100 mph, definitely fun to drive. Some dashboard fasteners will not be easily accessible once the front battery box is installed. The stock PCB precisely positioned the cell tap connectors (red) to minimize movement and stress on the connecting flex circuits (blue/orange) coming from the cells. I use the alphabet to paint words that become a beautiful and inspiring image in the reader's mind. EAS (Electric Auto Sports) has done the conversion on several vehicles, and they have not missed the Vanagon. gave me an idea. The BMS mount holes were drilled and revet-nuts inserted. In this article: eDub Services, Electric conversion, electric conversions, electric vans, Volkswagen (VW), Volkswagen Type II (Bus) Written By Jesper Berggreen Jesper had his perspective. She was immediately named Indie, as she was from a town called Andrews in Indiana. The box needs to be disassembled to get a better look and decide the best way to make a new reliable BMS cell tap connection to the bricks in this module.Once the wiring of the front box is complete, we begin connecting the coolant lines for both front and rear battery boxes to run the whole coolant system on the bench. Universal Electric Vehicle EV Conversion Kit. The default clutch-regen setting on the motor controller's "profile 2" is just right for that. With the motor installed, the clearance behind it looks good. The EV West VW Thing Kit is very unique in the fac EV Trainer Cart - Fully Assembled and Running - AC50 or Hyper9, Karmann Ghia EV Conversion Kit, AC Motor, Regen Braking, 1955-1974, Porsche 356 Speedster EV Conversion Kit, Regen Brakes, AC Motor, All Years, Porsche 911 EV Conversion Kit, Regen Brakes, AC Motor 1965-1986, Porsche 912 EV Conversion Kit, Regen Brakes, AC Motor 1965-1969, 1976, Porsche 914 EV Conversion Kit, Regen Brakes, AC Motor 1969-1976, Universal NetGain Hyper 9 120V EV Conversion Package - Motor, Inverter, Throttle, Instrument, Chill Plate, Volkswagen Super Beetle EV Conversion Kit Complete, Regen Brakes 1971-1979, Volkswagen VW Beetle/Bug EV Conversion Complete Kit, Regen Brakes, Battery Packs 1956-1977, Volkswagen VW Bus, Type 2, Samba EV Conversion Kit, Regen Brakes, AC Motor 1950-1979, Volkswagen VW Notchback EV Conversion Kit, AC Motor, Regen Braking, Type 3 1961-1973, Volkswagen VW Thing EV Conversion Kit, AC Motor, Regen Braking, 1968-1980. Beginning with the battery pack(s). Once that is done (enough), we will begin pulling the wiring for most components through the chassis. It also has a mode for checking wire continuity when we jiggle the harness. Upper left is a 1.5kW 6 element PTC unit. The charge inlet is installed in the stock fuel location. A homemade fuel-line tool on this. The car wasn't wrecked and had been driven less than 5000km. Quantity: 3 available 19 sold / See Feedback. In the past, we have installed aftermarket PCBs (not pictured) sold for this purpose, but they would cost >$300 forthis 10 module pack and require more labor time to install because of connector issues of their own. To avoid hazards is critical to have a BMS that properly monitors and manages the two strings and decides whether each string is allowed to connect the DC output bus that is used by the motor controller or any other loads. We sat down with one of our Lead VW Mechanics, Ben, to chat electric vehicle conversions. The BMS systems are operating as expected except for a diagnostic code that triggers when the charging process completes. This routing will go through the main center tube in the floor pan and was only recently firmed up because we had to see exactly how the inflexible coolant lines from the battery box modules would lay. We have . So lets begin at the beginning. When swerving aggressively, the roll is slight. Condition: Remanufactured. When evaluating battery type andsize we consider the energy consumption rate of the vehicle for typical driving. Jesper is founder ofLifelike.dk and a long-term investor in Tesla, rsted, and Vestas. We'll pop a hole in the top surface of the heat box (pictured a few paragraphs above). The affected area was cleaned with isopropyl and sealed with Conformal Coat. The price for an e-BULLI, featuring redesigned front and rear axles, starts at 64,900 ($69,500). The motor encoder severed a signal wire due to vibration and gave incorrect information to the motor controller, causing everything to (internally) blow up! It's the purest expression of the engineering that makes cars possible, and the thing they were engineered to do in the first place be driven. This part fits: Baywindow. With typical Tesla Model S battery modules, these connectors are not needed nor included. with further details discovered this week. Here'sa status update: Mechanical fit:It was assembled mechanically with modules, but without plumbing and wiring. With the high-level system decisions finished, we move into how we're going to properly and elegantly fit and wire these parts in the space available. 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