To determine battery capacity weuse the upper and lower ends of our range goal and multiply them by the estimated 250Wh/mile. Those plates will be ordered on Monday. The front and rear battery packs are fully wired, plumbed, and assembled. 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. More high current cables were routed, crimped, and installed by Chris. They can be campers, minibuses, ambulances, mobile bars, the list is endless. Amounts shown in italicised text are for items listed in currency other than Euros and are approximate conversions to Euros based upon Bloomberg's conversion rates. Theyve successfully completed countless electric vehicle conversions and now sell quite a few kits that make the process much easier.. I have been calling battery suppliers and posted on social media yesterday that we need 17 of these, plus 3 clamshell tops. The kit contains the following: Motor: HPEVS AC-50 Controller: Curtis 1238 650 Amp, 96 Volt Instrumentation: Xantrex Link Pro Shunt: Deltec 600 Amp It was assembled mechanically with modules, but without plumbing and wiring. Classic cars deserve to live on for many more generations, and electrification is the way to do that. 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. We thought wed run a few petrol campers for a while to feel out the market, then slowly convert them to electric. I have a Bachelors in Architecture from FAU. This kit comes with everything you need right down to the heat shrink tubing, and fuse holders. This is hard to say, as the costs for conversion were swallowed up in all the other costs for the business. So, as I said, road trips are how the best ideas come together, with my wife in the back keeping an eye on me. The content produced by this site is for entertainment purposes only. The assembly of the front box remains the priority. Solutions like this are often a gamble, but it worked great. Tear down to build up. VW Type 2 electric fuel pump conversion kits, high pressure Bosch fuel injection pumps and high performance rotary fuel pumps and fuel . The air-port (top image) distributes the warm air to 4 original windshield-defrost vents through the original 25mm defrost tubes. Add to List. Jesper had his perspective on the world expanded vastly after having attended primary school in rural Africa in the early 1980s. Volkswagen T4 T5 / T6 Transporter Conversion Furniture , DIY flat pack kits with tambour doors made in light weight ply . We didn't make them, but it's always nice when big shiny parts arrive for a project. This work falls more under the category of restoration than conversion, but every project has its challenges. A couple of hours later I was printing the orange parts in the image that are nested into a standard caulk gun. The final known bit of wiring (coolant pump, radiator fans) was completed. Condition: Remanufactured. However, technology has to be smart, clean, sustainable, widely accessible, and democratic in order to change the world for the better. I use the alphabet to paint words that become a beautiful and inspiring image in the reader's mind. We wanted to pay close attention to this because the battery location raised the center of gravity by about 18" from stock. This can easily cost an additional $2,000 - $3,000 on the low end for 2WD vans, and roughly double that for 4WD Syncros. The Bus also uses 911 suspension components and 964/944 disc brakes. I decided to buck up my ideas. through the Tesla modules is an important part of the conversion. 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. The motor was simultaneously inched forward to clear the rear body panel. 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. Not too hard, she replied. Since replacement parts are not available, some careful scraping exposed the flex circuits gold surface under the transparent Kapton coating. One phone call later we were on our way up north. With batteries that can take you up to 300-350 miles . Then the DC-DC 12V power supply fuse, heater/defroster which is amazing, and finally the charger fuse. It mates with the four steel tabs on the back-side of the original dash. Located all nonlabeled wires (16) and isolated them with tape for a 12v power-up test. On Revolt's website, it notes the forthcoming Tesla drive kit includes "a highly modified 400-kW Tesla Model S motor producing approximately . Answer: it doesn't matter anymore, really. We logged into the BMS,reviewedthe data captured at the moment of the fault. We can't put them into the car until this is confirmed. We were back on track and we werent giving up! And thecircuit to adapt the Master BMS power limit signal to the dash light is in and tested. 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! Slave BMS PCB modifications & cell tap harness wiring. Opinions and comments published on this site may not be sanctioned by and do not necessarily represent the views of CleanTechnica, its owners, sponsors, affiliates, or subsidiaries. Thomas Schmall, a member of the Board of Management of Volkswagen Group Components, commented on the project: The electrified Beetle combines the charm of our classic car with the mobility of the future. Like many, it was a dream of ownership but the concern for issues also kept my cash in my wallet. Battery Management System; Cables, protection and swivels; Complete Kits; DC converters; E-Bikes & Scooters; Electric outboard engines; Engines; Lithium Batteries . The box can be removed by the interior restoration folks, but it would be better to address these issuesnow. They'll need to be traced and decide what to do with them later. This increased power comes in an engine that's more compact, so your engine compartment is less cluttered than it was . Part Number: EPAS7479. Volkswagen Beetle/Bug Complete Kit 1956 - 1977, Volkswagen Bus / Samba / Type 2 1950 - 1979. The heater unit (with proper voltage element) has not arrived yet. Volkswagen (VW) has unveiled an electric conversion concept for its iconic Type 2 microbus to celebrate 20 years at its Electronics Research Laboratory (ERL) in California. The company converts cars for around Rs 2,40,000 and Rs 5,70,000. 1972 Volkswagen Type 2 Bus shows potential of e-Golf powertrain in vintage vehicles; Project e-Bus to be on display at the Petersen Automotive Museum on November 21; Herndon, VA Showcasing the possibilities of the e-Golf powertrain to motivate classic VW models, Volkswagen of America recently commissioned west coast electric vehicle conversion specialist EV West to construct . Weddle Industries stocks a wide variety of adapter kits to fit many common engine/transaxle combinations using VW and LS bolt patterns. No ride-height adjustment was needed from the stock torsion bar position. Directional grain texture was added and was just aggressive enough to work through the scratches. Another type of electric vehicle conversion uses an electric crate motor. A bit of non-EV conversion effort is occasional restoration work. Wiring is pulled through the firewall tube of the box end cover. An idea explored fora heater mounting and controls isto mount it in a console (yet-to-be-purchased) as seen above. The later classic, the T25, fixed a lot of the running issues plagued by the early campers, but we werent going to care about running issues. Plus, in my opinion, the T25 is a little ugly (send angry letters to my editor). 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. Both of these pumps have garden-hose-like flow, but we need higher pressure. A second pump (different type) wasn't good enough either. So lets begin at the beginning. The project had eaten our private investment, and then doubled that because of paying off the matched loan. Rather than add in-line fuses, we're adding one or twosmall fuse blocks in the engine compartment. Next week will be spent preparing the car to receive them. You've come to the heart of the question, really. We used a common universal pedal switch (top middle) at the rear of the car instead. Then the motor assembly slid forward over the transmission shaft and stoped against the adapter plate. This build retains the original clutch system, with a high torque clutch disc. Kit includes 3 high quality illuminated switches, plug in wiring harnesses, and switch mounting cases. The EV market is going from strength to strength, with conversions becoming more popular too. It will look a bit like we're going backward for a few days, but the new finish plan will be much better. These are critical for the BMS to monitor and balance the pack and a reliable fix is important. Three days later, my mum sent me the picture on the right. That would get the heat to passengers directly, and one or two hidden tubes could be routed to the windshield defrost ports. Chris has already been studying and preparing for the best routes on this build. With the removal of the rear-mounted petrol engine, theres the bonus of a usable amount of boot space. It suited us nicely but we never imagined we could ever own one. Putting your car under the knife is an intimidating thing, but its exciting as well. This conversion is one of the most often so a lot more resources are available., The price of these bad boys range from $15k to $30k.. Oops! The stock red "Oil light" becomes a system "Fault light". Completely controlled by wire, the charger was mounted in the old fuel compartment space. Cars need to have ample space for batteries as well. This revealed that the BMS detected an internal fault on its 5V rail voltage, reporting slightly above 6V. The new rim will fit, but we need a narrower tire on it. As of today, I found new connectors for. 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The 100-kilowatt. transmission adapter plate fit-tested, and ready to receive the motor (which hasn't arrived yet). The average cost of conversion is $30,000-$34,000 and takes about three months. Thankfully one tube was supplied with the car that we could use to verify dimensions. Driving down the A1 with my mum in the drivers seat and my wife in the back. The outer-most tubes each pass through another 3D printed adapter to make the shortest run to the stock dash vent ducts. The least powerful offer around a twenty to thirty five mile range and a top speed of thirty-five to forty miles per hour, creating an electric car that's useful for . The unit is supplied fully assembled, you just bolt the unit in and follow the wiring instructions. FREE delivery Wed, Mar 8 +7 colors/patterns. The Subaru engine conversion offers clear advantages for your Vanagon: The Subaru engine has 130 horsepower and 135 ft/lbs of torque compared to the Vanagon's 89 to 94 horsepower and 117 ft/lbs. And so, every morning, over a cup of coffee, I would stare out at Indie and wonder if we would ever get a solution. I'll spare you the boring images of that process. The water-out comes from the coolant connection nearest the positive-mostcells, one of which has the stock Tesla temperature sensor. One for each string. They call their conversion the "E-DUB" and it looks pretty good. The kit consists of a forklift loader that bolts to the stock Volkswagen transmission, a plate that adapts it, and a flywheel that . VW Bugs have been a popular platform for conversion to electric for decades. They will look nice when they go on the car next week. In that process, I determined there are10+ EV-related low voltage fuses and at least 4 relays all in the engine compartment. with further details discovered this week. 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. 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. They're capable of more than enough power that our system will draw 750A. A couple of months ago I introduced you to a UK company that converts classic cars to electric propulsion. That includes custom enclosures, multiple heater units, a center console to hide stuff and add fan controls, which the original car never had. The AC electric car conversion kit costs about a thousand dollars more than the DC, so not a lot of difference there. Price: $8,734.00 Add to Cart Details VW Bugs have been a popular platform for conversion to electric for decades. The simplest way is to buy a premade conversion kit that will inevitably save you time engineering your own bits and pieces, as well as money figuring it out on your own. Whilst their first film, Toy Story, was being made, the project took way longer than expected. All this to say it was more difficult to accommodate the P100D coolant line routes than expected. The throttle linkage and location were determined, a few parts were fabricated and polished (since it shows). This complete kit will deliver 140km safe driving distance, and will charge to full in a little under 8 hours. They started with a 1995 Vanagon and stripped the motor. Born in 1988, our family never had one. The lower-right image also shows a rectangular 3D printed cover that we designed to block the hole from the relocated fuse block. It is not a comprehensive step-by-step procedure, but we have included many details that future builders will find useful. Modules were inserted, and the fit was as good as we had hoped. It is staged for the KEP performance clutch, pressure plate, lightened flywheel, and related small parts that arrive next week. A clear protective guarding will go over this so the exposed high voltage is not accessible to curious fingers. In 2020, (Dr) Gilly Lacey is a Senior Lecturer in Electrical Engineering at Teeside University. Externally, only the coolant plumbing is a little different. To understand what car is best for an electric vehicle conversion we have to consider a few things: room for batteries, transmission, and popularity (or how models were produced). There will be a bit of a weight difference with the new engine adding 500kg to the scale. Closing the lower vents will send all the hot air to the windshield. The 818 is a kit car made by Factory Five that is based on Subaru WRX running gear. I didn't get an image of the template and location yet, but I'll post it next week. We now have enough P100D top clamshells to assemble the front pack and will begin that next week. You can find some for around $10-$15k in good working shape. Over the past month Ive been picking little pieces off the van to prep it for its new electric drivetrain. The plumbing in the rear involves the battery box lines, one pump, two radiators, and three multiport manifolds. You can get either one, and they're both equally good in a car, both simple to use and install. Wiring schematics are being updated forthe motor and controller. The Westfalia has been converted successfully to electric before. Installed by our technicians at eDub HQ in North Yorkshire, UK. Motorways are so boring, and it was great to explore the beautiful British countryside. In a Tesla, these boards monitor and balance the module as coordinated by the main Tesla BMS. Sourcing duct hoses of the proper size and adapting at couplers where needed was the challenge. A specialist in all things Porsche and VW, Zelectric offers electric conversions for a variety of different German classics, be it a 356, a Beetle, or even a Thing. While Chris was installing the cell tap wiring of the assembled front box, he discovered the torn cell tap circuit. Next, we'll mount the high current fuse and contactor (from the rear battery) and the motor controller and fluid cooling systems. We started dipping our toes into the hire market with a few bookings, but we also took the opportunity to test her ourselves. Hot air will also be ported to the windshield defrost ports. Add to basket. Applications: Engines: Ecotec, Chevy LS, Subaru, Toyota, VW, Honda 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. The USA-740-Radio from Custom Autosound arrived. By this point, so much money had been sunk into this project. Full fitting instructions and wiring diagrams are included with every unit. There must have been over 20 pages of sketches exploring possible routing to avoid the delay and cost of a new box side panel. Weddle Industries now stocks adapter kits to help you mate a VW style bell housing to most of today's common engine packages (see applications below).These kits contain an adapter plate and all necessary hardware to help fit the bare engine to the transaxle. Years Experience. Top left & right are the first drafts of a 3D model and its 3D print process set-up. He said, We have to do an episode on this! (Im still waiting for the call, FC.). The Parallel Configuration of the BMS units is set up and operational. What sets this apart is its range. When the plumbing is finalized, the rear pack will go into the car. The Swindon, on the other hand, goes for just about $2,506. People forever tinkering and fixing; making new or just patching up the old. We had some good chats with a company on the south coast of the UK that was for sale, but there were disagreements within the business and they didnt follow through. Routing of all the low-voltage power, signal, and data wires needed from front to rear went quickly. city car, including the single-speed gearbox. The nylon coolant line is not very flexible. For Alex and his wife Brita, VW Kombis are a full-time passion. Plus, spotting one on the motorway on bank holiday travels. This article was created to allow the customer to follow the high-level build activity. I've been working on various ways we plumb in a great (3kW+) heater and defrost system. The shaping and fitting of nearly every vent, trim piece, and switch had to be persuaded into place. The space in the box is very constrained, making hose overlaps a pinch risk. So, we're going to start with a big one, the Sven Hedin Crafter Volkswagen Westfalia Camper. 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 . I disagree with, but appreciate this observation. 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. This way, we can solder our cell tap wiring harness to the exposed side of the mounted BMS slave PCBs in place on the modules, without extra handling of the board, connectors, and flex circuits. 2023 - Intelligent Living Media Ltd. All Right Reserved. The 356 is a special Porshce. The rear battery box is powder coated and in position without batteries. We were in too deep and our only option was success. 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! With target battery capacity understood, we evaluate weight total and distribution, location, crush zone safety, etc. That went together as planned. After the front pack goes in, we won't have much room, so we are planning the front wire routing to be neat AND as serviceable as possible. The black connector is where the Tesla wiring harness was to connect to the module. INSTALLATION INCLUDES: Conversion Parts & Labor Stainless Steel Header Stainless Steel Exhaust Radiator and fans Small Car Aluminum Oil Pan New Engine Matched Clutch, Pressure Plate & Release Bearing Aluminum Bellhousing (for manuals) Powder Coated Engine Mount New Rubber Engine Mounts Heavy-Duty Stainless Muffler Supports & Clamps It is very close to front battery installation. Its continued to grow in popularity and from what I can tell from looking at the past few years of auctions on Bring a Trailer, they are appreciating. We want to avoid issues in the years to come. "It's is done!". For $17,000, enthusiasts can choose from a variety of first-generation Transporter bodies ranging from 1955 to 1967. A friend of mine has a mechanic friend who we called to see if he would be interested in the idea of helping us with the conversion. Other things done included sorting out the trunk's old wiring and pulling many out that will not be used. It is time to get registration, license plates, and registration! Slave BMS PCB modifications & cell tap harness wiring. Jesper is founder ofLifelike.dk and a long-term investor in Tesla, rsted, and Vestas. Theoretically with enough time and money you can convert any car to electric, however, some cars may be much easier than others. The cell taps and thermistors for the front battery box modules are wired. The circuit cycles the needle from empty to full to be sure it works, and to verify how we need to build the circuit for the BMS to send proper State Of Charge (SOC) signals to it. The kit used allows for fast charging at available plug-in points. 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. I've ordered what I believe to be the correct connectors, and have received a shipping confirmation. This way, the fasteners can be removed from this side without having to remove the battery pack on the other side of this wall.On the right, the two 6-fuse low voltage (12V) fuse blocks and 3 diode-equipped cube relays for the rear of the car are mounted on the door of the high voltage box. That draft was used to quickly check for interferences when in position on the module. 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. We sat down with one of our Lead VW Mechanics, Ben, to chat electric vehicle conversions. The stereo amp, speakers, and other parts arrived soon after ordering with exception of the stereo itself that should arrive any day. for Classic VW type 1 are well known for having issues. . When the flow is restricted too much on these pumps the pressure drops. During this project, we have explored many ways to get good heat in the remaining space. 599 subscribers Part 2 in a series showing you everything involved with converting a Volkswagen Kombi T2 Bay window bus to 100% electric Tesla power. No welding or floor work is required. The eDub platform features batteries, motor, charger and more in one simple package. T2 Bay Inlet Manifolds T2 Bay Fuel Tanks & Fuel Fillers Showing Items 1 - 36 of 324 1 2 3 4 5 Sort By Set Descending Direction Fillister Head Bolt N01-413-13 Quantity: 0.80 In Stock Add to Basket Exhaust Gasket for Single Hotspot Pre heater Pipe 113-251-263 Quantity: 2.05 In Stock Add to Basket EMPI Twin 34 EPC Carburettor Kit, Single Port The car was rolled back and forth to be sure the suspension had settled. 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. As long as healthy modules are purchased, they're a good value at around $230/kWh on today's market. Thank you for joining us on this ride. 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. To check clearances for the custom heater ducting and behind-the-dash access we put the front battery box into place one last time (as empty). With a growing interest among enthusiasts manufacturers are slowly beginning to create turn key solutions for electric vehicle conversions. It's browned because it must be heated to about 400F to expand and slip onto the motor shaft. We now have enough P100D top clamshells to assemble the front pack and will begin that next week. If we were to do the process again today with the same spec, the project would cost around 45,000 including the cost of. We launched eDub Conversions in 2019 to carry out this mission. Keep an eye out for more articles coming your way from eDub, including coverage of our Porsche 911 conversion, our Golf Mk2, and our BMW 700. We now have a routing plan and are proceeding to assemble! The red button shown in the lower-right image will operate the pump. The BMS harness has been wired to use these sensors so that itwill report what is likely to be the warmest cell temperatures. The coolant lines sweep down around the side and underneath the battery box to twoaluminumblock manifolds. With most of those parts missing, we're updating to an electric windshield washer fluid pump and reservoir. Having open space below it feels roomy. This left us with the perfect T2. That battery pack consumes a lot of space where other conversions have had room for luxuries like a heater.
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