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'll pop a hole in the top surface of the heat box (pictured a few paragraphs above). But as we build, a few things are requiring a bit more attention or follow-up than expected. Retro fit, electronic, speed-sensitive, power-assisted steering system to fit for Late Baywindow vans made from 1974 - 79. An idea explored fora heater mounting and controls isto mount it in a console (yet-to-be-purchased) as seen above. This week I uncrated all the Tesla P100D modules. It will only take one hour at an applicable plug-in point to replenish the battery to 75% capacity. However, technology has to be smart, clean, sustainable, widely accessible, and democratic in order to change the world for the better. This will avoid having someone else pull that pack for accesslater. The three low voltage wiring harnesses bundles exitingupwards will be enclosed in tubing and routed neatly to their destinations. 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. During this project, we have explored many ways to get good heat in the remaining space. We used a common universal pedal switch (top middle) at the rear of the car instead. Another hole will go through the upper firewall panel above it. With t the tightest allowable radius at about 5" or 6" they need to exit near the connections on each module. That's about a 50% increase! The unit is supplied fully assembled, you just bolt the unit in and follow the wiring instructions. The gland nuts for the cables to pass through are also installed. The wiring cleaned up nicely as well. At eDub Services, we take any form of donor vehicle. A few paragraphs above I mentioned a broken cell-tap flex-circuit on one of the battery modules. The HV pack fuses first. 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. eClassics also offers conversions of VW T2 and T3 vans. 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. Effective November 2022, Peace Vans Electric is officially accepting new customers for 2023 builds. Chris has already been studying and preparing for the best routes on this build. There are a number of kits you can purchase for Volkswagen VW Beetle conversions, depending on what you want out of your electric car. More BMS testing is needed to verify the settings are working, but much of that is more easily done when we're driving. 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. The engine rubber seal bits that were left have been cut off clean at the gasket attachment point. Click here to view more details about the P100D 6.3kWh coolant connectors. The stock controls were valves that were opened by cable controls. ), BidenHarris Administration Announces $74 Million to Advance Enhanced Geothermal Systems, In 2021, 20% Of Electricity In The US Was Generated From Renewable Sources, Stellantis Takes On Two Partners To Reduce EV Production Emissions, Redwood Materials Shares Lessons Learned After One Year Of Operation. 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. Note from Kits first-in-line editor, Jesper: I like the T25 its boxy! The final steps will be plumbing, leak testing, and cell tap harness testing. Upgrade to one-touch operation with AutoLc's one-touch power window control modules. 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. The customer had bought the van, gutted it (and I mean gutted! The image below it shows the amplifier mounted in place next to the steering column with speaker wires ready to be routed. For $17,000, enthusiasts can choose from a variety of first-generation Transporter bodies ranging from 1955 to 1967. Many people ask us how much Indie cost to build. VW Bay Window Power steering conversion kit Camper late early Bus Type 2 RHD LHD. VW Bugs have been a popular platform for conversion to electric for decades. 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. It will look a bit like we're going backward for a few days, but the new finish plan will be much better. Also not shown, are the stand-offs that hold the inverter/controller 1/4" off the firewall that it's mounted to. Taking off in 2nd or 3rd gear without clutching is just as we hoped. This means that the owner of a Classic VW Beetle can future-proof its pride and joy to fit into the clean world that nations are planning for. That includes custom enclosures, multiple heater units, a center console to hide stuff and add fan controls, which the original car never had. SHIFT EVis converting this 1970 VW beetle to electric power for a customer from Washington state. The throttle linkage and location were determined, a few parts were fabricated and polished (since it shows). To use all 10, we'll run two strings of 5 modules this way, in parallel. It probably doesn't help that the steel of this car experienced a front-end collision and may have tweaked geometry. 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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! We wanted to pay close attention to this because the battery location raised the center of gravity by about 18" from stock. The price for an e-BULLI, featuring redesigned front and rear axles, starts at 64,900 ($69,500). The company, named eDub Services, was founded by a young man named Kit Lacey, and since my piece on his business, he and I have been in conversation about this fascinating field of entrepreneurship. However, you need to keep in mind that these larger engines will almost certainly require a major rebuild of your transaxle too. With the high-level system decisions finished, we move into how we're going to properly and elegantly fit and wire these parts in the space available. The conversion uses VW electric components. If that is feasible, we reviewavailable motor and controller/inverter solutions that can providethe efficiency and powerwithin budget for this application. The BMS systems are operating as expected except for a diagnostic code that triggers when the charging process completes. Wiring is pulled through the firewall tube of the box end cover. Contact us now to get a quote and begin the conversion process. Front box in place. You can find some for around $10-$15k in good working shape. The whole plan for eDubs came together very quickly in my mind from the logo, to the style, to the interior, it all had to be perfect. 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. 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. 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.) Since replacement parts are not available, some careful scraping exposed the flex circuits gold surface under the transparent Kapton coating. More high current cables were routed, crimped, and installed by Chris. The stock yellow "Generator Light"becomes a system "Power Limit" warning light". All the best ideas do, in my opinion. available motor and controller/inverter solutions that can providethe efficiency and powerwithin budget for this application. These have more cells in each of the same-sized modules. As of today, I found new connectors for. In a Tesla, these boards monitor and balance the module as coordinated by the main Tesla BMS. It's not the box in the way. We drill a hole and rivet the nut into position. Condition: Remanufactured. This shop is usually a next-day lead time. It is resting (almost) in place, awaiting a few holes for mounting. I use the alphabet to paint words that become a beautiful and inspiring image in the reader's mind. The center console remains a valid option to put around what we've done if it remains appealing. To do this quickly, we took measurements and printed off several sheets of the orthogonal views above, and begin sketching out scenarios. . P100D Coolant connections and routing to manifolds. The electric opening mechanism of the folding roof improves comfort, especially during assembly and dismantling. There's no reason why we can't convert every single VW T2, is there! The painters didn't remove the heat and sound deadening material, so underneath lies a bit of clean-up. Subscribe below to receive occasional promotions and updates. I have been calling battery suppliers and posted on social media yesterday that we need 17 of these, plus 3 clamshell tops. VW T6.1 and T5 Campervan VW T25 Campervan VW T2 Campervan VW Kombi Day Van VW Split Screen Campervan Skilled Craftsmen. 1. When swerving aggressively, the roll is slight. Motorways are so boring, and it was great to explore the beautiful British countryside. What a ride it has been! There are 4 needed per module. Intelligent Living and its content is protected by international copyright law. So the garage had bought it back and now had it on sale. 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. I decided to buck up my ideas. In that process, I determined there are10+ EV-related low voltage fuses and at least 4 relays all in the engine compartment. What followed was an amazing summer. With target battery capacity understood, we evaluate weight total and distribution, location, crush zone safety, etc. By designing 3 elegant conversion packs specifically for VW T2 campers, featuring the new e60 pack, eDub Services have made your decision is so much simpler. We're now routing wires from front to rear for 12V power, CAN1, and CAN2 communications, plus BMS and charger signal wires. Your submission has been received! Another shot shows the blue paint on the otherwise black rubber engine bay seal. Nov 21, 2019. Its as simple as changing the cars clothes, sort of. "We can convert a Beetle in less than a month," he says. There is a bit more testing to confirm all battery protection is functioning as expected. Early or late was no issue to us. Completely controlled by wire, the charger was mounted in the old fuel compartment space. Slave BMS PCB modifications & cell tap harness wiring. 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 key information you need, such as range, charge speed, power and price, are easy to see and compare right here. Another type of electric vehicle conversion uses an electric crate motor. You can explore eDub Trips and book here. We are always working with suppliers and fabricators to lower this price to help more people get involved. The upper right image shows the underside of the car with the coolant pump visible on the left. This increased power comes in an engine that's more compact, so your engine compartment is less cluttered than it was . Battery capacity, of course. After deciding that the plan was a good one, we started the business dimensions. It cools to a zero clearance fit. This kit comes with everything you need right down to the heat shrink tubing, and fuse holders. The plumbing in the rear involves the battery box lines, one pump, two radiators, and three multiport manifolds. Discover the VW Camper Van conversion Process. It went in exactly as expected, thanks to a great deal of preparation the past few weeks. I talked to Kit about the concrete and chronological information on his rebuilds and how we could make it accessible for all of us curious about how such projects can be carried out. The BMS harness has been wired to use these sensors so that itwill report what is likely to be the warmest cell temperatures. Then the DC-DC 12V power supply fuse, heater/defroster which is amazing, and finally the charger fuse. This article was created to allow the customer to follow the high-level build activity. Now, here lay our issue: The motor and controller were manufactured by two different companies in the US, and both had failed. Our mechanic was based in a small village near Whitby and found a VW specialist in Sunderland, a few miles north. 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). The VW Type 1 Beetle Kit is very unique in the fact that it truly is a 'turn-key' kit. coolant connectors for the Tesla P100D battery modules, were included in the shipment. He agreed and we met for a pint at the local pub to talk it through. Fitting the stock-sized spare tire is a bonus. VW T2 Conversions. The COVID crisis (I had to mention it, sorry) has shut us down for a lot of the year, but when were open, were busy, which is great! of Options to build your perfect Campervan. This had to be mounted to cut and crimp their ends to the exact length needed. It takes a lot of force and without the tool, it is a lot like pushing a rope. There is more going on underneath the stainless steel panels. Quantity. The 12V heater fan wiring harness was completed, secured, and tested by operating the 3-speed switch on the dash. Thirty minutes later all 10 lines for the front box were pressed onto the Tesla P100D modules. The power delivery is about 173 pounds of instant torque, and its top speed is 100 mph, definitely fun to drive. The lower image shows the engine bay as it is today. To install the new BMS, we need to wire the new cell tap wiring harness and cell temperature wiring harness to each battery module. VW Bugs have been a popular platform for conversion to electric for decades. Space was made under the hood to mount the charger by re-aligning the right front brake line. A clear protective guarding will go over this so the exposed high voltage is not accessible to curious fingers. But this stage is not drive testing, yet. We now have enough P100D top clamshells to assemble the front pack and will begin that next week. They have twice the connections and odd-sized fittings as compared to the more common Tesla S modules. In the early 2000's, John took on the title as "Grumpy", and founded . Its hard enough when those regrets are just memories, but when you wake up every morning and stare out the window to see a beautiful green camper van with no hope of being restored; thats tough. Solutions like this are often a gamble, but it worked great. Volkswagen has teamed up with specialist firm eClassics based in Germany to provide the official conversion kit. The car drove excellent. Potentially the cheapest Porsche candidate on this list is the 914. For more recen The two orange dots on the left and right of the open blue area are foam plugs marking where two 1/2" bolt holes were drilled for the upper battery mount fasteners. The stock spring works, but not with enough safe margin. eDub's e80 pack takes the world's best supply of electric vehicle tech and puts it into the perfect vehicle; the classic camper. Bothlarge lines will be routed in parallel back to the pump and radiators. On Revolt's website, it notes the forthcoming Tesla drive kit includes "a highly modified 400-kW Tesla Model S motor producing approximately . Solutions like this are often a gamble, but it worked great. The upper right image shows the main contactor, and the PTC heater contactor is below it. 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. The DC cables to the motor inverter/controller (the top three) are all cut to length, crimped, and stabilized. Rather than wait for a tool, I looked up some clever ways people have accomplished similar press-fits like this. 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. I started a Photo Stream from day one of the project and my first picture was the eDub Logo. It's also quick, and fun to drive. Choose your VW conversion. When the flow is restricted too much on these pumps the pressure drops. The bed sits level with the rear engine shelf and make up a 6 foot bed when out in bed position. I know that we owe a figure with nearly 5 zeros on the end to private investors. The Bus also uses 911 suspension components and 964/944 disc brakes. The price of a Bharat Electric Car Conversion Kit in India is Approx. The front battery box is powder coated and in place without batteries. 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. A final assembly of parts in the motor compartment is underway. Next, the faulting BMS unit was moved to the I/O harness of the non-faulting BMS, and it worked as expected. They are already planning to do conversions of other models as well. 96. The original weighs around 800kg while the retrofitted electric version will weigh around 1,300kg. There areno big roadblocks anticipated regarding parts. The 356 is a special Porshce. The wiring diagram was updated to consolidate low voltage fuses and reduce wire runs between sections of the car. As long as healthy modules are purchased, they're a good value at around $230/kWh on today's market. The left and right side duct tubes will get replaced with directional and closable vents. The 912 is another good candidate, and if youre into Porsche this may be on the cheaper end of what you can get. through the Tesla modules is an important part of the conversion. I've updated the. It was manufactured in Easy Fit V-Tec design and offers approx. He said, We have to do an episode on this! (Im still waiting for the call, FC.). The lower right image shows it repaired and plugged into the slave BMS PCB on the module. Designed for electric vehicles in the 3000 to 4800 pound range, this a true highway-capable EV kit with excellent performance! 4.3 4.3 out of 5 stars (126) $71.96 $ 71. If we were to do the process again today with the same spec, the project would cost around 45,000 including the cost of. While Chris was installing the cell tap wiring of the assembled front box, he discovered the torn cell tap circuit. And the company sells a ready-to-fit . Volkswagen Beetle/Bug Complete Kit 1956 - 1977, Volkswagen Bus / Samba / Type 2 1950 - 1979. The components were carefully picked out to be the best available for the Bus, and fit and finish have been refined. Lower panels will be formed to help keep the weather out. 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. Electric Vehicle Conversion Kit: NetGain HyPer 9 Motor with Tesla Battery Read more. It works reliably and takes care of the complete set-up and closing process automatically. Located all nonlabeled wires (16) and isolated them with tape for a 12v power-up test. The box side-cover has slots intended for plumbing to exit, but those slots don't line up well with the P100D fitting locations. By this point, so much money had been sunk into this project. The ten coolant lines that exit the front battery box are now plumbed to the manifolds. The year is 2013. I am personally the wrong generation to love classic camper vans. But it's close. The air-port (top image) distributes the warm air to 4 original windshield-defrost vents through the original 25mm defrost tubes. Since the car was received without a 12V battery and mounts, no engine, fuel tank, radio, windscreen washer system, heater controls, etc. It's browned because it must be heated to about 400F to expand and slip onto the motor shaft. 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. Click through to see how they did it. We didn't make them, but it's always nice when big shiny parts arrive for a project. If youre interested in converting a VW T2 to electric, why not check out our webpage to see whats involved in electrifying a camper. The car wasn't wrecked and had been driven less than 5000km. We originally looked for a camper van business for sale. 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. It's fully plumbed, and wired to the car. Upper left is a 1.5kW 6 element PTC unit. It had the windows removed, and in the back, it had a bit of yellow/green interior seating (no thanks). Don't let anyone tell you a new VW Beetle dash installation is easy. (?) We're carefully bringing up different systems to avoid damaging anything that may be miswired. Kit includes 3 high quality illuminated switches, plug in wiring harnesses, and switch mounting cases. Type 2/T25 - Full-width VW Campervan Rock n Roll Bed. Volkswagen VW Bus, Type 2, Samba EV Conversion Kit, Regen Brakes, AC Motor 1950-1979 [EVW-T2-KIT] Price: $21,098.64 The EV West Air Cooled Volkswagen Type 2 Kit is very unique in the fact that it truly is a turn-key kit. The first step involves taking the vehicle to an eClassics firm (in Germany) for the installment of a kit. We've tried other pups, some in series, etc, trying to get the coolant flow up to par. Under the hood, the top image shows the stereo amplifier laying where the battery box bottom will be. So we decided to bite the bullet and go all electric with van number 1. For Alex and his wife Brita, VW Kombis are a full-time passion. There's also an amazing single-cab truck body on tap for $15,000, and you can. You can find one of these from $10-15k., The SW20 MR2 is an awesome JDM candidate for an ev conversion. The radiator, throttle, and possibly a pump or two have been included in the custom CAD design for the engine compartment floor plates. It puts out 81bhp, accelerates to 50mph in 8 secs and has a top speed of 93mph The claimed range is 124 miles. have been removed. This is the fuel display tester drivingthe stock fuel gauge. The stereo amp, speakers, and other parts arrived soon after ordering with exception of the stereo itself that should arrive any day. "It's is done!". Find the right tires for your conversion here! We're going to mount these intothe Beetle instead of the P85 pack mentioned earlier. How Do You Charge An Electric Car At Home? One for each string. Even specifically VW camper vans have a huge industry built around keeping them on the road. Advertise with CleanTechnica to get your company in front of millions of monthly readers. Not too hard, she replied. Some dashboard fasteners will not be easily accessible once the front battery box is installed. Instead of door locks, the Type 20 uses facial . 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! Removing this took two pounds off. 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 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. I guess this is why they have such a hobby shop following. The EV market is going from strength to strength, with conversions becoming more popular too. This clean-up was made sense to do now because wiring and access will be difficult after the conversion. While Chris was installing the cell tap wiring of the assembled front box, he discovered the torn cell tap circuit. I dropped it off at the tire store to return the tire and have it replaced. No. One by one, the high voltage fuses went in as each function was tested.