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Cars need to have ample space for batteries as well. The left-most orange cable is from the front battery pack area. Advertise with CleanTechnica to get your company in front of millions of monthly readers. However, technology has to be smart, clean, sustainable, widely accessible, and democratic in order to change the world for the better. A couple of hours later I was printing the orange parts in the image that are nested into a standard caulk gun. The Engine bay was cleaned up. There areno big roadblocks anticipated regarding parts. First Smart Microgrid In Zimbabwe Installed At Shopping Center In Harare, Renewables Face Two Major Challenges FUD & Connection Challenges, Flipping The Script On The Public Health & Wealth-Building Benefits Of Clean Energy, Nearly 1 In 3 Homes In Australia Covered In Solar Panels, Energy Security Amid Heightened Global Tensions. They came from a Tesla that was purchased for reverse engineering by a TESLA competitor. Jesper is founder ofLifelike.dk and a long-term investor in Tesla, rsted, and Vestas. At eDub Conversions, we aim to create full transparency with our costs. First, some quick specs on the more common engines: Vanagon Engine Conversion Specs : Common . What sets this apart is its range. I have a Bachelors in Architecture from FAU. What a ride it has been! It will be trimmed to length when the rear battery box (and its cable) is installed. To use all 10, we'll run two strings of 5 modules this way, in parallel. Next week will be spent preparing the car to receive them. Solutions like this are often a gamble, but it worked great. Since replacement parts are not available, some careful scraping exposed the flex circuits gold surface under the transparent Kapton coating. We managed to cross a few more things off our bucket list. 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. Chris has already been studying and preparing for the best routes on this build. That's 2kWh more than we'll need. The first 100 are available for a pre-order price of $2,990, and while we don't have . The painters didn't remove the heat and sound deadening material, so underneath lies a bit of clean-up. That draft was used to quickly check for interferences when in position on the module. The bottom left image shows the raw fuel gauge driver PCB (blank), and the right image shows it with components soldered to it. The kit contains the following: Motor: HPEVS AC-50 Controller: Curtis 1238 650 Amp, 96 Volt Instrumentation: Xantrex Link Pro Shunt: Deltec 600 Amp There is a bit more testing to confirm all battery protection is functioning as expected. We can't button it up until the P100D coolant connectors arrive and are verified for proper fit and pressure testing completed. At the bottom are the missing VW defrost ducts that just arrived. The difficulty of the conversion depends on the car you choose, the power you aim to have, and the range that you want. It works reliably and takes care of the complete set-up and closing process automatically. It all is looking super neat and tidy. He visited eDub HQ and fitted the new motor and controller. Space was made under the hood to mount the charger by re-aligning the right front brake line. Thirty minutes later all 10 lines for the front box were pressed onto the Tesla P100D modules. 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. We're now routing wires from front to rear for 12V power, CAN1, and CAN2 communications, plus BMS and charger signal wires. There were no system errors, no hiccups, no worries. 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. This week we worked out the specific placement of components that are not mounting directly to the battery enclosures. From Bring a Trailer it looks like you could expect to find one for around $40-50k. These would be tougher to find for a reasonable price as most seem to sell for around $100k if theyre in good shape. However, technology has to be smart, clean, sustainable, widely accessible, and democratic in order to change the world for the better. With the production of the original Volkswagen Beetle coming to an end this year when the final example rolled off the Puebla factory assembly line in Mexico it appeared as though this classic cars story was over for good. Army Of Spiral-Welding Wind Turbine Tower Trucks Sets Forth FromTexas? 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). The front battery box is powder coated and in place without batteries. So lets begin at the beginning. 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With target battery capacity understood, we evaluate weight total and distribution, location, crush zone safety, etc. The two large flat panels got three folds each and were ready for test fitting. Three days later, my mum sent me the picture on the right. We didn't make them, but it's always nice when big shiny parts arrive for a project. Mainly just my wife and I, but we also managed to get away with our friends and their daughter. $5,899.00. From 12 per month for 24 months. Doing this willnot have a detectable effect on balance. These images show the front box in position with the DC-DC converter, BMS, and main contactor with a high voltage fuse. Classic cars deserve to live on for many more generations, and electrification is the way to do that. Since the flex circuit repair, all of the slave BMS PCBs have been modified (traces cut). VW Bugs have been a popular platform for conversion to electric for decades. We now have a routing plan and are proceeding to assemble! If the Army can build electric tanks, anything is possible. It's similar to what's inside the black heater box assembly pictured below it. Do you have any regrets? VWCRAFTER DESIGNS. 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. 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. One manifold is for cold coolant-in, and the other is warm coolant-out. Another hole will go through the upper firewall panel above it. The stainless steel panels arrived with a dull eggshell finish and minor scratches. You can pick one of these up from as low as $8k. When swerving aggressively, the roll is slight. It will probably take longer than wed like, but as long as we dont give up, well get there. Effective November 2022, Peace Vans Electric is officially accepting new customers for 2023 builds. 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. The 3D printed solution cost is $0.50 each, which eliminates the need for the black 10 pin connector and allows visual confirmation that connectors are properly seated without removing the fixture. Just search eDub Services and youll find him. How hard would it be to convert a camper van to electric? I ask my mum. The first step involves taking the vehicle to an eClassics firm (in Germany) for the installment of a kit. I encouraged Kit to share the concrete information on his rebuilds with CleanTechnica in his own words. The left-to-right body roll is very slight and feels stock. The BMS mount holes were drilled and revet-nuts inserted. 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. Putting your car under the knife is an intimidating thing, but its exciting as well. The year is 2013. Click here to view more details about the P100D 6.3kWh coolant connectors. This length changed because the plumbing side of the front box was designed, fabricated and powder coated before we switched from standard Tesla modules to the P100D modules. 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.. The old dash panels, switches, glove box door, etc. Because of this experience, were trying really hard to systemise the conversion process, making conversions much more affordable and attainable. If that is feasible, we reviewavailable motor and controller/inverter solutions that can providethe efficiency and powerwithin budget for this application. Located all nonlabeled wires (16) and isolated them with tape for a 12v power-up test. We are experimenting with a higher pressure pump. But so far looking good. VW Bugs have been a popular platform for conversion to electric for decades. Years Experience. Much like maxing out luggage capacity, and in the same locations. Our dirt-cheap homemade electric Volkswagen runs! The front battery box is mechanically assembled and external wiring has begun. Electric vanagon conversion. The press-fit of the nylon hose onto the connectors requires a special tool with a 3 week lead time, and a pretty penny. Lower panels will be formed to help keep the weather out. Jesper is founder ofLifelike.dk and a long-term investor in Tesla, rsted, and Vestas. It is not a comprehensive step-by-step procedure, but we have included many details that future builders will find useful. It probably doesn't help that the steel of this car experienced a front-end collision and may have tweaked geometry. Our focus then shifted to the front in preparation for receiving that battery pack. Type 2/T25 - Full-width VW Campervan Rock n Roll Bed. Subscribe below to receive occasional promotions and updates. Another shot shows the blue paint on the otherwise black rubber engine bay seal. The VW Type 1 Beetle Kit is very unique in the fact that it truly is a 'turn-key' kit. We were back on track and we werent giving up! He said, We have to do an episode on this! (Im still waiting for the call, FC.). We purchase electric vehicle conversion kits from EV West. What sets this apart is its range. The holes for the DC-DC (on the front battery box) were tapped for assembly. Theres no reason why we cant convert every single VW T2, is there!(?) Rather than wait for a tool, I looked up some clever ways people have accomplished similar press-fits like this. All fasteners are threaded rivet-nuts. This is one of many tabs from the wiring diagram drawing set. 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. Racing is the soul of the auto industry. The original weighs around 800kg while the retrofitted electric version will weigh around 1,300kg. In a Tesla, these boards monitor and balance the module as coordinated by the main Tesla BMS. Rightly so, it's an exciting milestone to begin electrical testing. The 912 is another good candidate, and if youre into Porsche this may be on the cheaper end of what you can get. 2023 - Intelligent Living Media Ltd. All Right Reserved. You can get either one, and they're both equally good in a car, both simple to use and install. Yup, 5 of us in Indie it was great! You can kind of get an idea of a lot of older german cars and or other older manual small cars. Is there a limit to what you can run on electric, weight and size-wise? The charge inlet is installed in the stock fuel location. Kits UK-based company is called eDub Services. 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. The new spring arrives Monday. We found no leaks but discovered this pump won't work with these modules. For Alex and his wife Brita, VW Kombis are a full-time passion. This complete kit will deliver 90 miles safe driving distance, and will charge to full in a little under 8 hours. One by one, the high voltage fuses went in as each function was tested. The EV market is going from strength to strength, with conversions becoming more popular too. It is time to get registration, license plates, and registration! As of today, I found new connectors for. Choosing a model that has been converted before can save time and avoid unseen complications. A couple of months ago I introduced you to a UK company that converts classic cars to electric propulsion. More BMS testing is needed to verify the settings are working, but much of that is more easily done when we're driving. A final assembly of parts in the motor compartment is underway. we found many loose wires that needed to be dealt with. The starting cost of $70,100 requires you already have a Microbus. But they were rare, and expensive, and normally filled with rust. Then we'll make the high current series cables and install them between modules. Also, fuel lines and emissions parts, and tubing was removed. . This kit comes with everything you need right down to the heat shrink tubing, and fuse holders. The electric opening mechanism of the folding roof improves comfort, especially during assembly and dismantling. It's the new wider tire on the new wider rim. We are already working together to prepare the platform for the Bus. They call their conversion the "E-DUB" and it looks pretty good. It takes a lot of force and without the tool, it is a lot like pushing a rope. So we decided to bite the bullet and go all electric with van number 1. A homemade fuel-line tool on this. 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. The BMS systems are operating as expected except for a diagnostic code that triggers when the charging process completes. For this exercise we'll use a conservative 5.2kWh capacity value x 10 modules = 52kWh of capacity. BMS cell taps and temperature wiring is underway. It's fully plumbed, and wired to the car. Welcome to BUSARU. There's no reason why we can't convert every single VW T2, is there! The white connection mates to the new BMS cell temperature harness. It rode very smooth, even on the worst of downtown Albany roads. 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. The only hitch: You'll have to. All that's left there is to wire and stabilize the radiator fan wiring. That battery pack consumes a lot of space where other conversions have had room for luxuries like a heater. Van Clan's best hand picked campervan conversions. The van was perfect, a perfect shell with nothing in it. We launched eDub Conversions in 2019 to carry out this mission. transmission adapter plate fit-tested, and ready to receive the motor (which hasn't arrived yet). Add to basket. Note from Kits first-in-line editor, Jesper: I like the T25 its boxy! Wiring schematics are being updated forthe motor and controller. The owner is currently rebuilding the flat-six with an 964 intermediate shaft and GT3 . SHIFT EV is converting this 1970 VW beetle to electric power for a customer from Washington state. I heard stories of AA vans parking outside VW shows to save them making a long journey for a call out. That locks us into a maximum and minimum voltage range that our battery pack and other high voltage components must provide. Some versions have a more fragile flex circuit (Kapton and traces) like the modules pictured that we are building with. The DC cables to the motor inverter/controller (the top three) are all cut to length, crimped, and stabilized. The garage agreed to paint the van and do a left- to right-hand drive conversion for a reduced rate. I was starting . Upgrade to one-touch operation with AutoLc's one-touch power window control modules. 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. 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. Battery Management System; Cables, protection and swivels; Complete Kits; DC converters; E-Bikes & Scooters; Electric outboard engines; Engines; Lithium Batteries . gave me an idea. The Bus also uses 911 suspension components and 964/944 disc brakes. The space in the box is very constrained, making hose overlaps a pinch risk. Opening Tesla battery pack to remove modules. . We sat down with one of our Lead VW Mechanics, Ben, to chat electric vehicle conversions. btw Complete EV Conversion kit for a classic VW beetle, VW T1, VW T2 and Karman Ghia based with our EV HypE drive and various options for Lithium battery systems. An EV Conversion seems like a simple enough task . 1969 VW T2 Campervan electric conversion using a full 75 kW Tesla battery pack and Tesla Drive Unit. This complete kit will deliver 140km safe driving distance, and will charge to full in a little under 8 hours. This image shows the motor controller/inverter in position. Updates to wiring diagram to reflect this build. That includes custom enclosures, multiple heater units, a center console to hide stuff and add fan controls, which the original car never had. While they're not big nor long delays, today's updates are dedicated to a few of those things, listed below. If you have the vehicle and the dream, we have a conversion pack to suit. Weddle Industries stocks a wide variety of adapter kits to fit many common engine/transaxle combinations using VW and LS bolt patterns. All the best ideas do, in my opinion. No. Next, the faulting BMS unit was moved to the I/O harness of the non-faulting BMS, and it worked as expected. We have a tiny and exposed pedal assembly, making it difficult to add a switch there. But it's close. High current cables were started, and cooling systems parts were gathered and began getting mounted and plumbed. With typical Tesla Model S battery modules, these connectors are not needed nor included. 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. "We can convert a Beetle in less than a month," he says. It was manufactured in Easy Fit V-Tec design and offers approx. We've tried other pups, some in series, etc, trying to get the coolant flow up to par. The left and right side duct tubes will get replaced with directional and closable vents. It's on the opposite side of the blue steel panel that it is mounted. One phone call later we were on our way up north. 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. At eDub Services, we take any form of donor vehicle. In 2020, (Dr) Gilly Lacey is a Senior Lecturer in Electrical Engineering at Teeside University. Unlike other beetle conversions, this will have 63kWh on board. 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. 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. Volkswagen Beetle/Bug Complete Kit 1956 - 1977, Volkswagen Bus / Samba / Type 2 1950 - 1979. for Classic VW type 1 are well known for having issues. It is very stabilized once in place, and it is not relying on the solder bridges for mechanical strength. Solutions like this are often a gamble, but it worked great. 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. This part fits: Baywindow. Maybe this is what caught my interest as a conversion. Choose your VW conversion. The upper-left image wasafter Chris installed the shaft adapter so that it can accept the new lightened flywheel. The Westfalia has been converted successfully to electric before. So the garage had bought it back and now had it on sale. 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. . Are Lithium-Ion Batteries Recyclable? 2 - Self Opening, AC Motor 3 Phase Wire EV Motor Cable Set - 2/0 Orange, Brake Vacuum Reservoir Canister - Plastic, EV Pedestrian Trolly Bell - Horn Alternative, Gigavac GV200-MA EV Contactor - 4000 Amps Max - EV200 Replacement - 12 Volt Internal Economizer, Universal Starter Cover Plate - Fits VW, Porsche, and more, High Voltage Fuse 300 Volt 800 Amp A30QS800, EV West High Voltage High Current Fuse Holder Size 5, Remanufactured 2 Speed VW/Porsche Transmission for EV Motors, EV Specific Aluminum Lightweight Flywheel For Porsche and VW. These are critical for the BMS to monitor and balance the pack and a reliable fix is important. Then a fast touch with a fine tip solder iron is all it took to wick a nice solder bridge across each tear. The final known bit of wiring (coolant pump, radiator fans) was completed. Intelligent Living and its content is protected by international copyright law. The assembly of the front box remains the priority. Skilled Craftsmen. VW Type 2 Microfiches 68-79 Parts catalog (Volksteile) Pacific Parts International VWHelp.com Type IV: Secrets Revealed Bus Exhausts Fuel Injection Type 1 carb chart PDSIT exploded diagrams VW Bosch Distributors Distributor cross reference Bosch rotor numbers (Page 80) Bosch Ignition catalog Bus/914/411 ignition part numbers The rear battery box is powder coated and in position without batteries. This is a good candidate for conversion.. This week I uncrated all the Tesla P100D modules. Installed by our technicians at eDub HQ in North Yorkshire, UK. Without that perseverance from John and Steve, Pixar would never have made it and the world would have missed out. We have all the hose, connectors and manifold plumbing sizes figured out. The three low voltage wiring harnesses bundles exitingupwards will be enclosed in tubing and routed neatly to their destinations. VW Beetles are a popular option, says Mr Pauly, who has converted three in his workshop, and sold about 20 conversion kits with batteries and motor for owners to do the work themselves. The engine rubber seal bits that were left have been cut off clean at the gasket attachment point. To do this quickly, we took measurements and printed off several sheets of the orthogonal views above, and begin sketching out scenarios. The delays to research and test options are sometimes disappointing but must be done. The coolant lines sweep down around the side and underneath the battery box to twoaluminumblock manifolds. Thanksgiving week was short. This product was added to our catalog on Wednesday 01 January, 2014. 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