Also, more refinements to the wiring diagrams. . All the components that are mounted to the box are wired. Copyright 2023 CleanTechnica. The year is 2013. An idea explored fora heater mounting and controls isto mount it in a console (yet-to-be-purchased) as seen above. The testerpictured checks for proper pin-out and voltages at all connections. Since this image was captured, I've updated the coolant portions of the wiring diagram to show pumps, radiators, plumbing and ordered the parts to make visually appealing connections to the two chiller plate ports visible at the top of the controller/inverter box. We can't button it up until the P100D coolant connectors arrive and are verified for proper fit and pressure testing completed. Battery Management System; Cables, protection and swivels; Complete Kits; DC converters; E-Bikes & Scooters; Electric outboard engines; Engines; Lithium Batteries . ), BidenHarris Administration Announces $74 Million to Advance Enhanced Geothermal Systems, In 2021, 20% Of Electricity In The US Was Generated From Renewable Sources, Stellantis Takes On Two Partners To Reduce EV Production Emissions, Redwood Materials Shares Lessons Learned After One Year Of Operation. In addition to service work, he also began making parts by hand. The front battery box is powder coated and in place without batteries. Some dashboard fasteners will not be easily accessible once the front battery box is installed. It will probably take longer than wed like, but as long as we dont give up, well get there. I cannot guarantee any of the prices or products listed below. A couple of hours later I was printing the orange parts in the image that are nested into a standard caulk gun. However, you need to keep in mind that these larger engines will almost certainly require a major rebuild of your transaxle too. If youre interested in converting a VW T2 to electric, why not check out our webpage to see whats involved in electrifying a camper. Wiring schematics are being updated forthe motor and controller. eClassics also offers conversions of VW T2 and T3 vans. At long last: For weeks I've been telling everyone I'll test drive it this weekend, only to be sidelined by one problem or another. At eDub Conversions, we aim to create full transparency with our costs. We now have enough P100D top clamshells to assemble the front pack and will begin that next week. Some versions have a more fragile flex circuit (Kapton and traces) like the modules pictured that we are building with. Notice 1 of 3 bolts is missing from the back of the motor on the middle photo. The components were carefully picked out to be the best available for the Beetle, and fit and finish have been refined. During discharge, one string will its + and (-) outputs in parallel with the other string. It's about an hour from being installed and done, but it took much of a day to get the linkage and cable extension that would work. It is resting (almost) in place, awaiting a few holes for mounting. We drill a hole and rivet the nut into position. With the motor installed, the clearance behind it looks good. Disclaimer: I have no affiliation with EV West, and this is not a sponsored post. It's a lifesaver. The upper left image shows the coolant reservoir installed on the rear of the passenger-side edge of the battery box This edge is level when the pack is installed, leaving the reservoir as the highest point in the system. We are always working with suppliers and fabricators to lower this price to help more people get involved. But the P100D connectors are different and have no good alternative. We've actually been inside this one ourselves, and if it wasn't for the $100,000 price tag we'd snag one up pretty quickly! Next week we begin assembly of the modules into the boxes. The customer had bought the van, gutted it (and I mean gutted! Mainly just my wife and I, but we also managed to get away with our friends and their daughter. There are 4 needed per module. We have a tiny and exposed pedal assembly, making it difficult to add a switch there. Like many, it was a dream of ownership but the concern for issues also kept my cash in my wallet. The defrost air flow at the windscreen is impressive. Her PhD was The effect of smart grid utilisation on the degradation of an EV battery and she was one of the first in the country to have a Nissan Leaf on trial. It will look a bit like we're going backward for a few days, but the new finish plan will be much better. The clear polycarbonate guarding will keep curious fingers from touching the exposed high voltage post on the main contactor. The stock yellow "Generator Light"becomes a system "Power Limit" warning light". Its 12V wiring to the car is done and ready to plug it in on arrival. BMS cell taps and temperature wiring is underway. It's on the opposite side of the blue steel panel that it is mounted. A spring between them allows the linkage to travel after the switch is triggered, without over-stressing the switch. Disappointing, but a part of the journey. We sat down with one of our Lead VW Mechanics, Ben, to chat electric vehicle conversions. We've continued to wire and mount some final parts, but the throttle input mechanism had to be removed while we wait on a better "return" torsion spring to handle the stock pedal and cable linkage. They call their conversion the "E-DUB" and it looks pretty good. That's 2kWh more than we'll need. During this project, we have explored many ways to get good heat in the remaining space. It will only take one hour at an applicable plug-in point to replenish the battery to 75% capacity. Some with connectors, some cut clean, and other mysteries. This article was created to allow the customer to follow the high-level build activity. Thus it became obvious for him that technological advancement is necessary for the prosperity of all humankind, sharing this one vessel we call planet earth. I'm happy to report the car is plugged-in, charging, and balancing now. We managed to cross a few more things off our bucket list. And while educated a computer programmer and laboratory technician, working with computers and lab-robots at the institute of forensic medicine in Aarhus, Denmark, he never forgets what life is like having nothing. A routine step. That's the point. If you are embarking on a SubaruVanagon, Busaru, or Bugaru Subaru engine swap, you have come to the right place. Your submission has been received! No ride-height adjustment was needed from the stock torsion bar position. The lightened flywheel was even further lightened because I couldn't resist cutting off the ring gear since a starter motor will never be used to crank it over. To be exact, the company will extract the Beetles air-cooled flat-four-cylinder engine and replace it with the electric drivetrain from the existing e-up! This increased power comes in an engine that's more compact, so your engine compartment is less cluttered than it was . All this to say it was more difficult to accommodate the P100D coolant line routes than expected. The charge inlet is installed in the stock fuel location. Electric Vehicle Conversion Kit: NetGain HyPer 9 Motor with Tesla Battery Read more. Price: 249.99. In early February 2016, we had a visit from Matt, our mechanic. This series is the result, in Kit Laceys own words. Shipping calculated at checkout. They started with a 1995 Vanagon and stripped the motor. Jesper is founder ofLifelike.dk and a long-term investor in Tesla, rsted, and Vestas. And finally, I have a surprise that is 16% bigger. The car drove excellent. available motor and controller/inverter solutions that can providethe efficiency and powerwithin budget for this application. This means that the owner of a Classic VW Beetle can future-proof its pride and joy to fit into the clean world that nations are planning for. The car wasn't wrecked and had been driven less than 5000km. The press-fit of the nylon hose onto the connectors requires a special tool with a 3 week lead time, and a pretty penny. The affected area was cleaned with isopropyl and sealed with Conformal Coat. The tires are mounted on the new wheels with chrome valve stems and caps. VW of America and EV West have partnered to build an electrified Type 2 Bus. The 12V heater fan wiring harness was completed, secured, and tested by operating the 3-speed switch on the dash. It was another month of bittersweet feelings for Italys car sales in November. The stereo amp, speakers, and other parts arrived soon after ordering with exception of the stereo itself that should arrive any day. Skilled Craftsmen. Before cutting and assembling the coolant line to the new connectors, the minimum lengths from each module to its coolant manifold must be understood. This week we began executing the plumbing strategy. Fitting the stock-sized spare tire is a bonus. The black connector is where the Tesla wiring harness was to connect to the module. At eDub Services, we take any form of donor vehicle. It's a nice subtle finish and accepts large J1772 connectors. The painters didn't remove the heat and sound deadening material, so underneath lies a bit of clean-up. And while educated a computer programmer and laboratory technician, working with computers and lab-robots at the institute of forensic medicine in Aarhus, Denmark, he never forgets what life is like having nothing. To prevent hard regen from reducing the motor RPM too quickly, there needs to be a signal to the motor controller when the clutch pedal is pressed. The busy upper leftimage shows cell tap and thermistor wiring connected and shims (white) that precisely position and stabilize each of the 5 modules. The content produced by this site is for entertainment purposes only. 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. The power delivery is about 173 pounds of instant torque, and its top speed is 100 mph, definitely fun to drive. Answer: it doesn't matter anymore, really. This article was created to allow the customer to follow the high-level build activity. It's the new wider tire on the new wider rim. The original dash valve switch still rotates to operate the wiper motor. The components were carefully picked out to be the best available for the Bus, and fit and finish have been refined. It's fully plumbed, and wired to the car. We started dipping our toes into the hire market with a few bookings, but we also took the opportunity to test her ourselves. The left and right side duct tubes will get replaced with directional and closable vents. And so, every morning, over a cup of coffee, I would stare out at Indie and wonder if we would ever get a solution. At the bottom are the missing VW defrost ducts that just arrived. Theoretically with enough time and money you can convert any car to electric, however, some cars may be much easier than others. The starting cost of $70,100 requires you already have a Microbus. Lower panels will be formed to help keep the weather out. Space was made under the hood to mount the charger by re-aligning the right front brake line. The plumbing under the car is complete leaving only the battery connections upfront to connect. Modules were inserted, and the fit was as good as we had hoped. We went with a 3kW off-the-shelf heater/fan unit neatly tucked under the firewall in the center. By designing 3 elegant conversion packs specifically for VW T2 campers, featuring the new e60 pack, eDub Services have made your decision is so much simpler. We launched eDub Conversions in 2019 to carry out this mission. Click here to view more details about the P100D 6.3kWh coolant connectors in a separate blog post. Kit includes 3 high quality illuminated switches, plug in wiring harnesses, and switch mounting cases. We are verifying fit, final wire routing, and service access before the final installation of the battery modules into the box. By this point, so much money had been sunk into this project. It is very close to front battery installation. The 912 is another good candidate, and if youre into Porsche this may be on the cheaper end of what you can get. The only hitch: You'll have to. There areno big roadblocks anticipated regarding parts. eDub Trips is going strong, taking people on incredible staycations around North Yorkshire. Quantity. With most of those parts missing, we're updating to an electric windshield washer fluid pump and reservoir. As of today, I found new connectors for. The white paper is preventing wire stripping remnants from falling into the radiators while we work in this area. 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. Upper left is a 1.5kW 6 element PTC unit. Thank you! 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. Its PTC element was the wrong voltage, but everything else was identical. We'll pop a hole in the top surface of the heat box (pictured a few paragraphs above). While Chris was installing the cell tap wiring of the assembled front box, he discovered the torn cell tap circuit. So, as I said, road trips are how the best ideas come together, with my wife in the back keeping an eye on me. We found no leaks but discovered this pump won't work with these modules. But it's close. VW Bugs have been a popular platform for conversion to electric for decades. 1. After we got back, we tested a few more things and began buttoning up the wiring harness, installing high voltage guarding, and doing other cosmetic work. Nov 21, 2019. When we began to route our Orion BMS cell tap wires, we discovered one module had a torn-off flex circuit (bottom right). I'm told it's coming, but In the meantime, we've been using one that we had on the shelf with the same outer dimensions, but a wrong pack voltage element. For much of this maneuvering, there was less than a 1/4" of clearance between the body and the motor until the splined transmission shaft lined up with the splined hole in the motor coupler. You've come to the heart of the question, really. This isroutine and is getting worked out. Years Experience. The motor controller is programmed, up and running! It's not a photogenic step in the process. What sets this apart is its range. These beautiful steel boxes were already set to undergo any transformation. There will be a bit of a weight difference with the new engine adding 500kg to the scale. Add to List. Using VW Beetle Electric Conversion Kit. All of its connectors extend to the drivers' side for easy access. A bit of non-EV conversion effort is occasional restoration work. Battery enclosures sold separately. The space in the box is very constrained, making hose overlaps a pinch risk. Kits UK-based company is called eDub Services. 10 cm more height in the foot area compared to conventional sleeping roofs. We must replace the stock PCB (green) with a reliable connection method. I know that we owe a figure with nearly 5 zeros on the end to private investors. The two large flat panels got three folds each and were ready for test fitting. The 356 is a special Porshce. We settled on the Hyper9 X1 system. I've updated theP100D module coolant connector pagewith further details discovered this week. Now, here lay our issue: The motor and controller were manufactured by two different companies in the US, and both had failed. Choose your VW conversion. That battery pack consumes a lot of space where other conversions have had room for luxuries like a heater. Many VW Bugs have been converted in the past with efficiency claims between 200 and 300 Watt-hour per mile (Wh/mi). VW T2 Conversions. The new spring arrives Monday. We've had concerns with the pressure required for the P100D Tesla modules not being good enough with typical pumps. This article was created to allow the customer to follow the high-level build activity. This is normal at this stage. They have twice the connections and odd-sized fittings as compared to the more common Tesla S modules. It was produced from thin aluminum to verify edge geometry and other features such as radiator mounting, etc. So, both units had to be sent back, and then the two companies had to decide how fo fix the problem. Wheels are in! Damage was discovered and fixed. Can you see it? We can't put them into the car until this is confirmed. With a growing interest among enthusiasts manufacturers are slowly beginning to create turn key solutions for electric vehicle conversions. Perfectly timed; eDub have unveiled a conversion pack for classic cars, including the classic VW camper vans, capable of achieving 235 miles to a charge with CCS rapid charging in under an hour. So the garage had bought it back and now had it on sale. We modified the 3D print port sizes to make use of stock VW hose sizes and repositioned the ports to clear the battery box and other obstacles. Front box in place. Opening Tesla battery pack to remove modules. My wife and I were married in 2009 and had a splitty camper as our wedding car. Next, we'll train the wire looms into position and start making the high current series connections between modules. Volkswagen T4 T5 / T6 Transporter Conversion Furniture , DIY flat pack kits with tambour doors made in light weight ply . The box side-cover has slots intended for plumbing to exit, but those slots don't line up well with the P100D fitting locations. Commonluy used Tesla S and X battery modules are about 5.2kWh (depending on some model variants sucy as the 4.5kWh, 5.3kWh, 5.6kWh, and 6.2kWh. They had an imported American van that was bought for a customer. I talked to Kit about the concrete and chronological information on his rebuilds and how we could make it accessible for all of us curious about how such projects can be carried out. The coolant plumbing linesare now complete from front to rear, including the pump and motor controller. It is installed easily and has a great old-school look. Next week will be spent preparing the car to receive them. A couple of months ago I introduced you to a UK company that converts classic cars to electric propulsion. SHOP. (On the other hand, the Army has a nearly unlimited budget, too.) Re-routing of some under-box wires and the hood-release cable were things we knew were needed. Closing the lower vents will send all the hot air to the windshield. The lower image shows the engine bay as it is today. On the other side, we are plumbing the modules from a 100kWh pack (6.3kWh each). But they were rare, and expensive, and normally filled with rust. After reviewing a few types of batteries in different scenarios, the Tesla battery modules used in the Tesla Model S and X are a good option for this build in several ways. I'm also reaching out to a local traveling Tesla tech to check new part availability. Early campers were iconic. And the company sells a ready-to-fit . The final known bit of wiring (coolant pump, radiator fans) was completed. Minor trimming was needed, but the parts fit into place well. 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. Intelligent Living and its content is protected by international copyright law. The project had eaten our private investment, and then doubled that because of paying off the matched loan. If you have the vehicle and the dream, we have a conversion pack to suit. Once we know how we want to seal up the final engine bay, we'll see if we need to remove that bead or finish things in a better way. Then we'll make the high current series cables and install them between modules. VW Transporter T2 EV kit (3) VW Transporter T3 EV Kit (2) VW Transporter T4 / T5 EV Kit (2) VW Beetle EV Kit (3) Smart Roadster EV kit (2) Smart Fortwo EV Kit (2) Productcategorien. To use all 10, we'll run two strings of 5 modules this way, in parallel. Rightly so, it's an exciting milestone to begin electrical testing. The Microbus shown here was actually built for an Omaze giveaway in early 2021, so needless to say, it's dressed to the nines with 21st-century components. Upgrade to one-touch operation with AutoLc's one-touch power window control modules. 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Completely controlled by wire, the charger was mounted in the old fuel compartment space. Another hole will go through the upper firewall panel above it. It takes a lot of force and without the tool, it is a lot like pushing a rope. 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There must have been over 20 pages of sketches exploring possible routing to avoid the delay and cost of a new box side panel. The HV pack fuses first. You can kind of get an idea of a lot of older german cars and or other older manual small cars. These would be tougher to find for a reasonable price as most seem to sell for around $100k if theyre in good shape. The high voltage wiring is simply two wires to a high voltage contactor mounted on the front battery box. Top left & right are the first drafts of a 3D model and its 3D print process set-up. I've been working on various ways we plumb in a great (3kW+) heater and defrost system. However, the dash is in bad shape as seen below. The two orange dots on the left and right of the open blue area are foam plugs marking where two 1/2" bolt holes were drilled for the upper battery mount fasteners. 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. 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. Complete Bay Window alternator conversion kits, voltage regulators, Volkswagen campervan split charge relays (for big stereo systems and other high-drain electrical accessories) and . In the early 2000's, John took on the title as "Grumpy", and founded . 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. Interior workwas to follow this conversion project. We're going to mount these intothe Beetle instead of the P85 pack mentioned earlier. They're capable of more than enough power that our system will draw 750A. . A final assembly of parts in the motor compartment is underway. Updates to wiring diagram to reflect this build. The best car to convert to electric is a classic VW Beetle. Our dirt-cheap homemade electric Volkswagen runs! The water-out comes from the coolant connection nearest the positive-mostcells, one of which has the stock Tesla temperature sensor. Before connecting it to the slave BMS PCB this and all other cell tap connectors were inspected and probed to be sure no other tears were present. VW Crafter Sven Hedin Westfalia Camper. "It's is done!". That was such a fun drive. Steve Jobs (with a large bank balance due to Apple success) had seen talent in John Lasseter and his ability to create beautiful animation. Is there a limit to what you can run on electric, weight and size-wise? The assembly of the front box remains the priority. The AC electric car conversion kit costs about a thousand dollars more than the DC, so not a lot of difference there. speedometer is stock, the fuel gauge will display correct State Of Charge (SOC). Thanksgiving week was short. This is a good candidate for conversion.. The most recent iteration has the Bus powered by a built Porsche 911 flat-six connected to 1989 G50 five-speed manual transmission with a Kennedy Engineered Products clutch with RSR flywheel. Find the right tires for your conversion here! Removing this took two pounds off. 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). Yup, 5 of us in Indie it was great! I've ordered what I believe to be the correct connectors, and have received a shipping confirmation. He had been given confirmation that both the motor and controller would be repaired under warranty and returned to us to fit! The price for an e-BULLI, featuring redesigned front and rear axles, starts at 64,900 ($69,500).