We wanted to pay close attention to this because the battery location raised the center of gravity by about 18" from stock. The plumbing under the car is complete leaving only the battery connections upfront to connect. I recently bought TESLA battery modules from a Tesla P100D. Some versions have a more fragile flex circuit (Kapton and traces) like the modules pictured that we are building with. Beginning with the battery pack(s). With the removal of the rear-mounted petrol engine, theres the bonus of a usable amount of boot space. $5,899.00. To install the new BMS, we need to wire the new cell tap wiring harness and cell temperature wiring harness to each battery module. Designed for electric vehicles in the 3000 to 4800 pound range, this a true highway-capable EV kit with excellent performance! Top left & right are the first drafts of a 3D model and its 3D print process set-up. (?) The rear battery box is bolted together except for the side walls. The upper right image shows the underside of the car with the coolant pump visible on the left. The difficulty of the conversion depends on the car you choose, the power you aim to have, and the range that you want. There is a bit more testing to confirm all battery protection is functioning as expected. 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. Minor trimming was needed, but the parts fit into place well. 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! Interior workwas to follow this conversion project. 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. If youd like a more in-depth explanation you can check out my other article: Converting Your Car To Electric. Three days later, my mum sent me the picture on the right. We drill a hole and rivet the nut into position. 1. P100D Coolant connections and routing to manifolds. Its as simple as changing the cars clothes, sort of. It's not the box in the way. It's browned because it must be heated to about 400F to expand and slip onto the motor shaft. 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. We used a common universal pedal switch (top middle) at the rear of the car instead. Discover the VW Camper Van conversion Process. The left-to-right body roll is very slight and feels stock. We specialise in VW camper vans because we know how they work, and more importantly, know what components fit where! On the other side, we are plumbing the modules from a 100kWh pack (6.3kWh each). If you have the vehicle and the dream, we have a conversion pack to suit. Space was made under the hood to mount the charger by re-aligning the right front brake line. 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. Whilst their first film, Toy Story, was being made, the project took way longer than expected. The high voltage wiring is simply two wires to a high voltage contactor mounted on the front battery box. Early campers were iconic. Without that perseverance from John and Steve, Pixar would never have made it and the world would have missed out. She moved! Electric GT makes a product that looks actually somewhat like a V8, but electric and the price tag is a whopping $33,949. This week I uncrated all the Tesla P100D modules. This article was created to allow the customer to follow the high-level build activity. 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. Another shot shows the blue paint on the otherwise black rubber engine bay seal. Most of the kits on this list are provided by an electric car garage in southern California, EV West. Applications: Engines: Ecotec, Chevy LS, Subaru, Toyota, VW, Honda This revealed that the BMS detected an internal fault on its 5V rail voltage, reporting slightly above 6V. Once that is done (enough), we will begin pulling the wiring for most components through the chassis. The center console remains a valid option to put around what we've done if it remains appealing. Until this week, we were using a heater box that we had in stock to mock up the system. That locks us into a maximum and minimum voltage range that our battery pack and other high voltage components must provide. The heater unit (with proper voltage element) has not arrived yet. The electric version of the classic VW Microbus has been on the horizon, but. So, back to the camper. Yet, even though its heavier, it will be faster the 81bhp electric power source should make the car accelerate from a standstill to 50mph (80.5kmph) in eight seconds and onto a top speed of 93mph (150kmph.) Each of our electric conversion projects are totally unique and tailored to your needs and desires. Subscribe below to receive occasional promotions and updates. Disappointing, but a part of the journey. 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. Add to List. Steve Jobs (with a large bank balance due to Apple success) had seen talent in John Lasseter and his ability to create beautiful animation. So lets begin at the beginning. It may not look like much, but for the previous 6 months, Indie had been sitting on the opposite side of the drive! The PCBs are all mounted and ready for harness wiring. The components were carefully picked out to be the best available for the Beetle, and fit and finish have been refined. Sorry, we have detected unusual traffic from your network. Thankfully one tube was supplied with the car that we could use to verify dimensions. They have twice the connections and odd-sized fittings as compared to the more common Tesla S modules. eClassics also offers conversions of VW T2 and T3 vans. 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. We're carefully bringing up different systems to avoid damaging anything that may be miswired. 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. Motorways are so boring, and it was great to explore the beautiful British countryside. 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. What sets this apart is its range. For Alex and his wife Brita, VW Kombis are a full-time passion. The electric opening mechanism of the folding roof improves comfort, especially during assembly and dismantling. 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. Potentially the cheapest Porsche candidate on this list is the 914. The car was rolled back and forth to be sure the suspension had settled. You can find one of these from $10-15k., The SW20 MR2 is an awesome JDM candidate for an ev conversion. For more on this surprisingly complex topic,see the. High current cables were started, and cooling systems parts were gathered and began getting mounted and plumbed. Is there a limit to what you can run on electric, weight and size-wise? I started a Photo Stream from day one of the project and my first picture was the eDub Logo. Doing this willnot have a detectable effect on balance. 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. That went together as planned. 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). I spoke with him today and we should have parts Monday. The press-fit of the nylon hose onto the connectors requires a special tool with a 3 week lead time, and a pretty penny. No welding or floor work is required. 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. The left and right side duct tubes will get replaced with directional and closable vents. The rear battery box is powder coated and in position without batteries. Companies like Swindon in the United Kingdom and Electric GT in the United States, are selling electric motors that (theoretically) are drop-in replacements for your internal combustion engine. That battery pack consumes a lot of space where other conversions have had room for luxuries like a heater. 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. The eDub platform features batteries, motor, charger and more in one simple package. that was recently been decided on has been back-ordered due to an unavailable 12V blower fan. We went with a 3kW off-the-shelf heater/fan unit neatly tucked under the firewall in the center. Copyright 2023 CleanTechnica. It had the windows removed, and in the back, it had a bit of yellow/green interior seating (no thanks). The first 100 are available for a pre-order price of $2,990, and while we don't have . 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. Intelligent Living and its content is protected by international copyright law. That's 2kWh more than we'll need. Redbulls this month! SHOP. Thanksgiving week was short. I was starting . The box side-cover has slots intended for plumbing to exit, but those slots don't line up well with the P100D fitting locations. SHIFT EV is converting this 1970 VW beetle to electric power for a customer from Washington state. There areno big roadblocks anticipated regarding parts. Your submission has been received! It was stripped and primed but nothing else. Theyve successfully completed countless electric vehicle conversions and now sell quite a few kits that make the process much easier.. One for each string. When we began to route our Orion BMS cell tap wires, we discovered one module had a torn-off flex circuit (bottom right). PTC (electric) heater, Operated by stock heater controls, With target battery capacity understood, we evaluate weight total and distribution, location, crush zone safety, etc. T5 T6 Slim LWB Kits; PRO KITS; T2 BAY; Ford Custom; Traffic Vivaro Primstar; Larger Vans; Sprinter & VW Crafter; Kitchen Pods; . Next, we'll train the wire looms into position and start making the high current series connections between modules. I've updated the. I cannot guarantee any of the prices or products listed below. The front battery box is mechanically assembled and external wiring has begun. The upper-left image wasafter Chris installed the shaft adapter so that it can accept the new lightened flywheel. 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. We sat down with one of our Lead VW Mechanics, Ben, to chat electric vehicle conversions. The gland nuts for the cables to pass through are also installed. The thick dirt had built up over decades. There's also an amazing single-cab truck body on tap for $15,000, and you can. The original dash valve switch still rotates to operate the wiper motor. VW T2 Conversions. There's no reason why we can't convert every single VW T2, is there! 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. So, for me, a camper van would be perfect, but which one? The switch is anchored to the adapter plate bolt. All types have pros and cons. Oops! The throttle linkage and location were determined, a few parts were fabricated and polished (since it shows). I know that we owe a figure with nearly 5 zeros on the end to private investors. Lower panels will be formed to help keep the weather out. The upper right image shows the main contactor, and the PTC heater contactor is below it. The AC electric car conversion kit costs about a thousand dollars more than the DC, so not a lot of difference there. Much like maxing out luggage capacity, and in the same locations. A final assembly of parts in the motor compartment is underway. New Flywheel assembly, a KEP Stage II pressure plate, and a four puck clutch on a lightened flywheel - plus starter ring gear removed. transmission adapter plate fit-tested, and ready to receive the motor (which hasn't arrived yet). Please slide to verify. 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. This product was added to our catalog on Wednesday 01 January, 2014. Unlike most kits on ebay that come with a small, 8-inch or 9-inch diameter motor, this kit includes a . The rear pack is now mounted behind the rear seat. Need faster charging, ask us about CHAdeMO DC Fast Charging. The box had to be disassembled to repair it (as described above). The wiring diagram was updated to consolidate low voltage fuses and reduce wire runs between sections of the car. eDub's e80 pack takes the world's best supply of electric vehicle tech and puts it into the perfect vehicle; the classic camper. First, some quick specs on the more common engines: Vanagon Engine Conversion Specs : Common . We convert your air-cooled VW buses and vans into electric vehicles. Thank you for joining us on this ride. More hose was ordered and the latest 3D airport is being printed (lower left) as I write this update. The engine rubber seal bits that were left have been cut off clean at the gasket attachment point. From Bring a Trailer it looks like you could expect to find one for around $40-50k. She was immediately named Indie, as she was from a town called Andrews in Indiana. A homemade fuel-line tool on thisz28 threadgave me an idea. Before cutting and assembling the coolant line to the new connectors, the minimum lengths from each module to its coolant manifold must be understood. Slave BMS PCB modifications & cell tap harness wiring. The new spring arrives Monday. Unfortunately, the CNC programmer had an emergency come up and has been out for two days. It's similar to what's inside the black heater box assembly pictured below it. Wiring schematics are being updated forthe motor and controller. It was assembled mechanically with modules, but without plumbing and wiring. He said, We have to do an episode on this! (Im still waiting for the call, FC.). This clean-up was made sense to do now because wiring and access will be difficult after the conversion. It suited us nicely but we never imagined we could ever own one. But I should mention it comes with quite a few very promising specs. It all is looking super neat and tidy. Full fitting instructions and wiring diagrams are included with every unit. While they're not big nor long delays, today's updates are dedicated to a few of those things, listed below. During discharge, one string will its + and (-) outputs in parallel with the other string. It is not a comprehensive step-by-step procedure, but we have included many details that future builders will find useful. The busy upper leftimage shows cell tap and thermistor wiring connected and shims (white) that precisely position and stabilize each of the 5 modules. Effective November 2022, Peace Vans Electric is officially accepting new customers for 2023 builds. Something went wrong while submitting the form. Part Number: EPAS7479. Upper left is a 1.5kW 6 element PTC unit. We're going to mount these intothe Beetle instead of the P85 pack mentioned earlier. It's also quick, and fun to drive. They will look nice when they go on the car next week. There will be a bit of a weight difference with the new engine adding 500kg to the scale. Complete Bay Window alternator conversion kits, voltage regulators, Volkswagen campervan split charge relays (for big stereo systems and other high-drain electrical accessories) and . eDub Trips is going strong, taking people on incredible staycations around North Yorkshire. Its 12V wiring to the car is done and ready to plug it in on arrival. The car drove excellent. Scopema RIB seat beds , VW T5 T6 rear and side windows . Products - Any - Volkswagen Swingaxle ('61-'68 T1, '61-'67 Bus) Type 1 IRS ('69 & Later) 002 Bus ('68-'75 Type 2 IRS) The van was perfect, a perfect shell with nothing in it. So the garage had bought it back and now had it on sale. It cools to a zero clearance fit. Shes a bit more qualified than you might expect. There's a 2" diameter black steel tube extending from the battery box that pokes through the firewall where the positive and negative high current cables (orange) are visible in the upper left of this image. Rather than wait for a tool, I looked up some clever ways people have accomplished similar press-fits like this. The box can be removed by the interior restoration folks, but it would be better to address these issuesnow. This can easily cost an additional $2,000 - $3,000 on the low end for 2WD vans, and roughly double that for 4WD Syncros. Then the DC-DC 12V power supply fuse, heater/defroster which is amazing, and finally the charger fuse. However, its not advised to drive at top speeds for too long as the range will quickly disappear. It all started with a road trip. What followed was an amazing summer. Mainly just my wife and I, but we also managed to get away with our friends and their daughter. This is the fuel display tester drivingthe stock fuel gauge. The SW20 MR2 is an awesome JDM candidate for an ev conversion. Quantity: 3 available 19 sold / See Feedback. A few paragraphs above I mentioned a broken cell-tap flex-circuit on one of the battery modules. There is more going on underneath the stainless steel panels. The front and rear battery packs are fully wired, plumbed, and assembled. We logged into the BMS,reviewedthe data captured at the moment of the fault. This week we worked out the specific placement of components that are not mounting directly to the battery enclosures. This isroutine and is getting worked out. Our focus then shifted to the front in preparation for receiving that battery pack. At eDub Services, we take any form of donor vehicle. The starting cost of $70,100 requires you already have a Microbus. Electric Vehicle Conversion Kit: NetGain HyPer 9 Motor with Tesla Battery Read more. 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. 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. The final cable is on the rear battery pack, the BMS and temperature sensor wiring are all secured. The space in the box is very constrained, making hose overlaps a pinch risk. This week we began executing the plumbing strategy. All this to say it was more difficult to accommodate the P100D coolant line routes than expected. How Do You Charge An Electric Car At Home? All the best ideas do, in my opinion. Hot air will also be ported to the windshield defrost ports. The HV pack fuses first. The motor had to be staged at the proper angle as the car was lowered down over it to get the motor/clutch assembly started around the transmission input shaft. The final steps will be plumbing, leak testing, and cell tap harness testing. Kit includes 3 high quality illuminated switches, plug in wiring harnesses, and switch mounting cases. We'll pop a hole in the top surface of the heat box (pictured a few paragraphs above). Damage was discovered and fixed. If the Army can build electric tanks, anything is possible. "We can convert a Beetle in less than a month," he says. The eDub Platform. The motor was simultaneously inched forward to clear the rear body panel. It takes a lot of force and without the tool, it is a lot like pushing a rope. VW Bugs have been a popular platform for conversion to electric for decades. Battery enclosures sold separately. A bit of non-EV conversion effort is occasional restoration work. . 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. The original weighs around 800kg while the retrofitted electric version will weigh around 1,300kg. Lite-Steer is simple enough to fit for most enthusiasts with some basic mechanical knowledge. Answer: it doesn't matter anymore, really. The lower right image shows it repaired and plugged into the slave BMS PCB on the module. . All the components that are mounted to the box are wired. 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. 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. of Options to build your perfect Campervan. The wiring harnesses and connections were completed, trained into position and where needed, protected with convoluted tubing. The stock yellow "Generator Light"becomes a system "Power Limit" warning light". Easy to reach and still in the standard VW configuration. It's fully plumbed, and wired to the car. 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. The 100-kilowatt. Over the past month Ive been picking little pieces off the van to prep it for its new electric drivetrain. It is not a comprehensive step-by-step procedure, but we have included many details that future builders will find useful. 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. Slave BMS PCB modifications & cell tap harness wiring. Plus, spotting one on the motorway on bank holiday travels. No. A new Elcon TC charger meant we could charge at 7kW, so a long drive from North Yorkshire to Malvern for the ElectrAA Show was now possible. The conversion uses VW electric components. Volkswagen has teamed up with specialist firm eClassics based in Germany to provide the official conversion kit. The classic camper vans, VWs up until the late 1980s, were just as famous for breaking down as they were for their looks and charm. I am personally the wrong generation to love classic camper vans. A couple of months ago I introduced you to a UK company that converts classic cars to electric propulsion. . Routing of all the low-voltage power, signal, and data wires needed from front to rear went quickly. 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The BMS systems are operating as expected except for a diagnostic code that triggers when the charging process completes. These images show the front box in position with the DC-DC converter, BMS, and main contactor with a high voltage fuse. I've been working on various ways we plumb in a great (3kW+) heater and defrost system. The space in the box is very constrained, making hose overlaps a pinch risk. Theoretically with enough time and money you can convert any car to electric, however, some cars may be much easier than others. Another type of electric vehicle conversion uses an electric crate motor. Click through to see how they did it. I use the alphabet to paint words that become a beautiful and inspiring image in the reader's mind. Front box in place. Also not shown, are the stand-offs that hold the inverter/controller 1/4" off the firewall that it's mounted to. 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. The nylon coolant line is not very flexible. The DC cables to the motor inverter/controller (the top three) are all cut to length, crimped, and stabilized. 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. The front battery box is powder coated and in place without batteries. In early February 2016, we had a visit from Matt, our mechanic. Installed by our technicians at eDub HQ in North Yorkshire, UK. In that process, I determined there are10+ EV-related low voltage fuses and at least 4 relays all in the engine compartment.