Easy to reach and still in the standard VW configuration. Rexnamo Electro-Electric Car Conversion Kit. Electric bike conversion kits 2022 - A guide on giving your bike a.4-barrel carburetor to fuel injection conversion kits for 250-600 HP V8 engines No laptop required Fits any square (Holley 4150) . The ten coolant lines that exit the front battery box are now plumbed to the manifolds. Before cutting and assembling the coolant line to the new connectors, the minimum lengths from each module to its coolant manifold must be understood. As we had to take the shortest route, we bumbled through the country lanes and A roads, over the Peak District and beyond. And isnt it a good job he did! Also not shown, are the stand-offs that hold the inverter/controller 1/4" off the firewall that it's mounted to. The left-most orange cable is from the front battery pack area. Removing this took two pounds off. The stock yellow "Generator Light"becomes a system "Power Limit" warning light". With the availability of a conversion kit that will transform the classic Beetle into a new-age electric car that you can charge at home. With t the tightest allowable radius at about 5" or 6" they need to exit near the connections on each module. The air-port (top image) distributes the warm air to 4 original windshield-defrost vents through the original 25mm defrost tubes. I didn't get an image of the template and location yet, but I'll post it next week. I recently bought TESLA battery modules from a Tesla P100D. 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. 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. The stock PCB precisely positioned the cell tap connectors (red) to minimize movement and stress on the connecting flex circuits (blue/orange) coming from the cells. What sets this apart is its range. It all started with a road trip. That was such a fun drive. Its as simple as changing the cars clothes, sort of. 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 image shows the motor controller/inverter in position. Three days later, my mum sent me the picture on the right. There areno big roadblocks anticipated regarding parts. Most of the kits on this list are provided by an electric car garage in southern California, EV West. It will be trimmed to length when the rear battery box (and its cable) is installed. The airflow to all six ports is excellent. 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. At eDub Services, we take any form of donor vehicle. This is one of many tabs from the wiring diagram drawing set. eClassics also offers conversions of VW T2 and T3 vans. 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. We're going to mount these intothe Beetle instead of the P85 pack mentioned earlier. Click here to view more details about the P100D 6.3kWh coolant connectors in a separate blog post. Not too hard, she replied. Upper left is a 1.5kW 6 element PTC unit. The electric opening mechanism of the folding roof improves comfort, especially during assembly and dismantling. More BMS testing is needed to verify the settings are working, but much of that is more easily done when we're driving. 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. We have also seen support become more available and parts easier to source. The SW20 MR2 is an awesome JDM candidate for an ev conversion. 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. Taking off in 2nd or 3rd gear without clutching is just as we hoped. The upper right image shows the main contactor, and the PTC heater contactor is below it. For this exercise we'll use a conservative 5.2kWh capacity value x 10 modules = 52kWh of capacity. 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. We also decided the 12V fuse panel will be relocated so that its backside wire connections can be accessible in the future for serviceability. city car, including the single-speed gearbox. 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.. Unfortunately, the CNC programmer had an emergency come up and has been out for two days. The components were carefully picked out to be the best available for the Beetle, and fit and finish have been refined. It puts out 81bhp, accelerates to 50mph in 8 secs and has a top speed of 93mph The claimed range is 124 miles. The front seats are now in. He had been given confirmation that both the motor and controller would be repaired under warranty and returned to us to fit! 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. Having the heater in the cabin (vs. under the hood) will allow it to recirculate the cabin air, heating more effectively. We made it to the Spring Dub festival in Harrogate that March (more of a Golf scene to be honest, but hey) and we tested camping. 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It rode very smooth, even on the worst of downtown Albany roads. Over the past month Ive been picking little pieces off the van to prep it for its new electric drivetrain. Since the flex circuit repair, all of the slave BMS PCBs have been modified (traces cut). The red button shown in the lower-right image will operate the pump. 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 This board has a combination of components that suit the gauge on this car. The 3D printed manifold pictured below will port air directly from the cabs heater box to feed 4 ports with short tubes to the windshield defroster vents. They are already planning to do conversions of other models as well. It is very stabilized once in place, and it is not relying on the solder bridges for mechanical strength. Thirty minutes later all 10 lines for the front box were pressed onto the Tesla P100D modules. The Bus also uses 911 suspension components and 964/944 disc brakes. The clear polycarbonate guarding will keep curious fingers from touching the exposed high voltage post on the main contactor. In this case, we narrowed it down toone of the smaller HPEVS brushless AC motors or one of the NetGain brushless SRPM AC HyPer9 motors. Find the right tires for your conversion here! The USA-740-Radio from Custom Autosound arrived. Sourcing duct hoses of the proper size and adapting at couplers where needed was the challenge. 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. With the motor installed, the clearance behind it looks good. Feedback ID The EV market is going from strength to strength, with conversions becoming more popular too. It's not the box in the way. The battery cables in the car were cut to length and lugs crimped on. 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 stock controls were valves that were opened by cable controls. Can you see it? 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 holes for the DC-DC (on the front battery box) were tapped for assembly. that was recently been decided on has been back-ordered due to an unavailable 12V blower fan. Disappointing, but a part of the journey. The sound/heat deadening matt was looking ratty and was removed from the trunk because we need to mount some parts to the steel wall. It is time to get registration, license plates, and registration! The first step involves taking the vehicle to an eClassics firm (in Germany) for the installment of a kit. 5 Lakhs. In a Tesla, these boards monitor and balance the module as coordinated by the main Tesla BMS. The nylon coolant line is not very flexible. Based in Ghaziabad, Rexnamo Electro offers retrofitted electric cars and conversion kits for the last ten years. That's 2kWh more than we'll need. A couple of hours later I was printing the orange parts in the image that are nested into a standard caulk gun. The box side-cover has slots intended for plumbing to exit, but those slots don't line up well with the P100D fitting locations. The assembly of the front box remains the priority. 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. It's similar to what's inside the black heater box assembly pictured below it. Weddle Industries stocks a wide variety of adapter kits to fit many common engine/transaxle combinations using VW and LS bolt patterns. It is not a comprehensive step-by-step procedure, but we have included many details that future builders will find useful. Damage was discovered and fixed. We are always working with suppliers and fabricators to lower this price to help more people get involved. They're capable of more than enough power that our system will draw 750A. So the garage had bought it back and now had it on sale. 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. Nothing else will be in this motor compartment. The old dash panels, switches, glove box door, etc. We drill a hole and rivet the nut into position. Add To Boot. We were back on track and we werent giving up! 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. It is very close to front battery installation. Slave BMS PCB modifications & cell tap harness wiring. Years Experience. Each of our electric conversion projects are totally unique and tailored to your needs and desires. The eDub platform features batteries, motor, charger and more in one simple package. P100D Coolant connections and routing to manifolds. To avoid hazards is critical to have a BMS that properly monitors and manages the two strings and decides whether each string is allowed to connect the DC output bus that is used by the motor controller or any other loads. There were no system errors, no hiccups, no worries. The high voltage wiring is simply two wires to a high voltage contactor mounted on the front battery box. Add to basket. It's browned because it must be heated to about 400F to expand and slip onto the motor shaft. The power delivery is about 110 pounds of instant torque, and is a lot of fun to 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. Next week we begin assembly of the modules into the boxes. 2023 - Intelligent Living Media Ltd. All Right Reserved. Thanksgiving week was short. Lower panels will be formed to help keep the weather out. The space in the box is very constrained, making hose overlaps a pinch risk. Retro fit, electronic, speed-sensitive, power-assisted steering system to fit for Late Baywindow vans made from 1974 - 79. Copyright 2023 EV West Privacy Notice |Conditions of Use. If you are embarking on a SubaruVanagon, Busaru, or Bugaru Subaru engine swap, you have come to the right place. 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. From Bring a Trailer it looks like you could expect to find one for around $40-50k. 1. 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. Nov 21, 2019. A homemade fuel-line tool on thisz28 threadgave me an idea. Theres no reason why we cant convert every single VW T2, is there!(?) 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. 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. With t the tightest allowable radius at about 5" or 6" they need to exit near the connections on each module. The frame is fully powder coated and comes with all fixings needed to assemble it. The stereo and final dash replacement piece have arrived. The front and rear battery packs are fully wired, plumbed, and assembled. 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. of Options to build your perfect Campervan. If that is feasible, we reviewavailable motor and controller/inverter solutions that can providethe efficiency and powerwithin budget for this application. So, to start us off, we needed the following; We sourced a startup loan to get us started, with a business plan to convert a camper to electric and then hire it out for holidays around Yorkshire. This routing will go through the main center tube in the floor pan and was only recently firmed up because we had to see exactly how the inflexible coolant lines from the battery box modules would lay. Other things done included sorting out the trunk's old wiring and pulling many out that will not be used. VW Bugs have been a popular platform for conversion to electric for decades. The motor encoder severed a signal wire due to vibration and gave incorrect information to the motor controller, causing everything to (internally) blow up! These images show the front box in position with the DC-DC converter, BMS, and main contactor with a high voltage fuse. I like to compare this period to a story I once heard about the origins of Pixar. This is the fuel display tester drivingthe stock fuel gauge. We're carefully bringing up different systems to avoid damaging anything that may be miswired. It takes a lot of force and without the tool, it is a lot like pushing a rope. The center image shows the radiatorsand fans mounted, with the throttle pot box in the upper left. (?) In early February 2016, we had a visit from Matt, our mechanic. The crate motor produces a claimed 450 kW, or 550 hp. The manifolds transition the five small lines to one bigger tube. The harness is laid out where we expect it to stay. They call their conversion the "E-DUB" and it looks pretty good. The driving range of one full charge is about 124 miles. We started dipping our toes into the hire market with a few bookings, but we also took the opportunity to test her ourselves. The gray assembly (not used) is smaller, uses nichrome elements much like a hairdryer, and multiple units can be located where needed much like a hairdryer. Many variables contribute to this efficiency such as weight, tires, motor efficiency, speed, etc. People forever tinkering and fixing; making new or just patching up the old. The final steps will be plumbing, leak testing, and cell tap harness testing. Now, here lay our issue: The motor and controller were manufactured by two different companies in the US, and both had failed. Kits UK-based company is called eDub Services. Since the flex circuit repair, all of the slave BMS PCBs have been modified (traces cut). Top left & right are the first drafts of a 3D model and its 3D print process set-up. speedometer is stock, the fuel gauge will display correct State Of Charge (SOC). I still like AC better, but they both have their virtues. I always find important decisions like this are best decided over a local Yorkshire pint! As long as healthy modules are purchased, they're a good value at around $230/kWh on today's market. Army Of Spiral-Welding Wind Turbine Tower Trucks Sets Forth FromTexas? 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. VW Bugs have been a popular platform for conversion to electric for decades. Now, back to the road trip and my mums response. It had the windows removed, and in the back, it had a bit of yellow/green interior seating (no thanks). There's no reason why we can't convert every single VW T2, is there! We are already working together to prepare the platform for the Bus. You've come to the heart of the question, really. The BMS systems are operating as expected except for a diagnostic code that triggers when the charging process completes. It's also quick, and fun to drive. Without that perseverance from John and Steve, Pixar would never have made it and the world would have missed out. Once that is done (enough), we will begin pulling the wiring for most components through the chassis. In 2020, (Dr) Gilly Lacey is a Senior Lecturer in Electrical Engineering at Teeside University. Zelectric Microbus. The affected area was cleaned with isopropyl and sealed with Conformal Coat. I'm also reaching out to a local traveling Tesla tech to check new part availability. The defrost air flow at the windscreen is impressive. Sorry, we have detected unusual traffic from your network. We managed to cross a few more things off our bucket list. While they're not big nor long delays, today's updates are dedicated to a few of those things, listed below. The white paper is preventing wire stripping remnants from falling into the radiators while we work in this area. That side is assembled and bolted into place. This complete kit will deliver 150km safe driving distance for a 1000kg vehicle, and will charge to full in a little under 8 hours. 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. High current cables were started, and cooling systems parts were gathered and began getting mounted and plumbed. Unlike most kits on ebay that come with a small, 8-inch or 9-inch diameter motor, this kit includes a . Battery capacity, of course. Externally, only the coolant plumbing is a little different. We can't button it up until the P100D coolant connectors arrive and are verified for proper fit and pressure testing completed. A couple of months ago I introduced you to a UK company that converts classic cars to electric propulsion. It cools to a zero clearance fit. We are also providing Beetle owners with a professional conversion solution, using production parts of the highest quality. Then the motor assembly slid forward over the transmission shaft and stoped against the adapter plate. All the components that are mounted to the box are wired. Jesper is founder ofLifelike.dk and a long-term investor in Tesla, rsted, and Vestas. 19691979. We now have a routing plan and are proceeding to assemble! The 12V fuse panel landed here. 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. VW Type 2 electric fuel pump conversion kits, high pressure Bosch fuel injection pumps and high performance rotary fuel pumps and fuel . Contact us now to get a quote and begin the conversion process. It was assembled mechanically with modules, but without plumbing and wiring. We have built our conversions into 5 different packs to give prospects a clear expectation of what will be required. 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. So, back to the camper. When the plumbing is finalized, the rear pack will go into the car. What began way back in 1938 led to a worldwide craze with a total of 21 million Beetles built throughout the cars history. So, as I said, road trips are how the best ideas come together, with my wife in the back keeping an eye on me. For more recen Some with connectors, some cut clean, and other mysteries. While Chris was installing the cell tap wiring of the assembled front box, he discovered the torn cell tap circuit. Choose your VW conversion. Wiring schematics are being updated forthe motor and controller. At the bottom are the missing VW defrost ducts that just arrived. 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. Not shown, the new spare tire (narrower) is on the rim and fits into the stock location under the hood. Slave BMS PCB modifications & cell tap harness wiring. To install the new BMS, we need to wire the new cell tap wiring harness and cell temperature wiring harness to each battery module. 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. Learn more about the eDub Platform here> The nylon coolant line is not very flexible. 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. 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. It probably doesn't help that the steel of this car experienced a front-end collision and may have tweaked geometry. As a family, weve since gone through 3 Nissan Leafs, 2 BMW i3s, and a Kia e-Niro. With target battery capacity understood, we evaluate weight total and distribution, location, crush zone safety, etc. No ride-height adjustment was needed from the stock torsion bar position. The stainless steel panels arrived with a dull eggshell finish and minor scratches. Price: 249.99. VW T6.1 and T5 Campervan VW T25 Campervan VW T2 Campervan VW Kombi Day Van VW Split Screen Campervan I have been calling battery suppliers and posted on social media yesterday that we need 17 of these, plus 3 clamshell tops. Click here to view more details about the P100D 6.3kWh coolant connectors. With a growing interest among enthusiasts manufacturers are slowly beginning to create turn key solutions for electric vehicle conversions. There is more going on underneath the stainless steel panels. Located all nonlabeled wires (16) and isolated them with tape for a 12v power-up test. The components were carefully picked out to be the best available for the Bus, and fit and finish have been refined. A homemade fuel-line tool on this. After sitting in the driver and passenger seats imagining a center console, one begins to realize the small car would feel very cramped for average-sized or bigger people. Even specifically VW camper vans have a huge industry built around keeping them on the road. The BMS mount holes were drilled and revet-nuts inserted. The lower right image shows it repaired and plugged into the slave BMS PCB on the module. They will look nice when they go on the car next week. This left us with the perfect T2. The wiring cleaned up nicely as well. 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. The 100-kilowatt. Advertise with CleanTechnica to get your company in front of millions of monthly readers. By this point, so much money had been sunk into this project. Volkswagen has teamed up with specialist firm eClassics based in Germany to provide the official conversion kit. An idea explored fora heater mounting and controls isto mount it in a console (yet-to-be-purchased) as seen above. Driving down the A1 with my mum in the drivers seat and my wife in the back. Today was the first test drive. This can easily cost an additional $2,000 - $3,000 on the low end for 2WD vans, and roughly double that for 4WD Syncros. To verify the minimum requirements, we're going to fill and test the modules within the front and rear battery boxes on the bench (as a whole system) before installing them.
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