EV Conversion
- Hits: 1512
This site will be used to document the process of converting a VW Beetle from it's original 1600 air-cooled engine, to an electric drive. My goal is to have a fun / quick off the line vehicle with advanced / modern controls. Not looking to create a daily driver, so range is not super important. Fun and high tech is the goal (well, as high tech as I can with a 47 year old vehicle) . Some planned features include an HMI for operation and monitoring, nice sound system, and additional bells and whistles available to an EV.
Check out:
Conversion Process Blog
for detailed info on the conversion.
Conversion Tasks
- Hits: 984
| Item | Date Complete | Man Hours | |
| General clean up / get organized | 1/1/2020 | 4 | |
| Get PA title (not possible without being PA resident) | n/a | ||
| Remove engine | 1/10/2020 | 4 | |
| Test new DC motor | 2/25/2020 | 1 | |
| Breakdown New DC Motor | 2/29/2020 | 3 | |
| Detailed measurement and model of motor, flywheel, and trans for connection design | 4/1/2020 | 1 | |
| Rebuild/tune up transaxle | |||
| Remove clutch assembly from motor | 4/1/2020 | 1 | |
| General clean up of motor area | 4/15/2020 | 2 | |
| Remove gas tank, and rough clean of area | 2/19/2020 | 4 | |
| Debug existing wiring and ID interface signals | 7/1/2020 | 3 | |
| Measure and model: | |||
| - Back seat area for battery storage/sub woofer | |||
| - Engine compartment for motor and controller mounting | 6/1/2020 | 2 | |
| - Engine compartment for sheet metal / plastic covers | |||
| - Front trunk for future battery area | |||
| Design motor, clutch, and tranny connection assembly | 7/1/2020 | 40 | |
| Order motor mounting | |||
| Preliminary controls / wiring plan | 7/2/2020 | 4 | |
| Document detailed parts list (initial and future) | |||
| Design battery box and controls mounting | |||
| Decide how to handle existing wiring | |||
| Buy batteries, motor, and controls in order to complete and verify designs | |||
| Buy mounting fabrications | |||
| Assemble all | |||
| Test run | |||
| Get Ohio Title | |||
| Add fancy controls and features | |||
| Rebuild braking and suspension systems | |||
| Restore vehicle |
