Last rideNew motorDC/DC ConverterCommon situationSpagetti factory
OwnerRoger Daisley
LocationPullman, Washington US map
Web/EmailWebPage email image
Vehicle1986 Volkswagen Cabriolet
Great little car. In the ICE configuration, the car had been previously lowered about two inches. After conversion, I had springs wound that would maintain that ride height.
MotorWarfield ImPulse 9 Series Wound DC
9.25"; 129 lbs; 60 ft/lbs torque;
DrivetrainStandard VW 5-speed manual transmission. Synthetic gear oil used.
ControllerCurtis 1231B
Works well in this car. Mounted on 1/4" aluminum plate supplied by Electro Automotive. I may later add a 6' DC fan, that I have on-hand, for cooling, if it seems needed. Can't have too much cooling. For now, no problems, even with a heavy foot and 90+ deg. air temp.
Batteries16 Interstate US125, 6.00 Volt, Lead-Acid, Flooded
Good reliable reasonably priced batteries. (I would rather have Optima Yellow Tops, but I'd also "rather not" spend the required $4,000!)
System Voltage96 Volts
ChargerManzanita Micro PFC20
Good piece of equipment by Rich Rudman. I usually charge from a 120VAC 20-amp outlet I installed. I find that after a 25-mile run, it recharges the pack in about five-six hours, including an hour of low current "balancing" at the end.
HeaterNone yet. I removed and saved all the original VW heater/AC housing and hardware. This fall I will build a 120V electric "quartz type" ceramic heater into the heater box. I will use the original VW heater fan to circulate the heated air.
DC/DC ConverterCC Power C400
A little "pricey," but looks nice and seems to get the job done. What more can you ask?
InstrumentationState-Of-Charge (SOC); Amps 0-500; Volts: 10-15
Top Speed65 MPH (104 KPH)
Maybe higher: Since both the battery pack and motor are new, I haven't pushed it to the limit yet. So far, easily cruises on the nearby state highway at 55 MPH ... even on modest hills.
AccelerationAcceptable, but no dragster. I can merge with traffic just fine. Again, with a new motor and battery pack, max. performance is yet to be determined
Range40 Miles (64 Kilometers)
So far, runs of 25 miles are easily handled. Upon return, the SOC meter usually reads 50%+ remaining. (I haven't determined if that's a "real" 50% or a "mythical 50%" that evaporates much quicker than the first 50%. Stay tuned.
Watt Hours/MileUsing my "Killawatt" and recharging at the limiting 15-amps, I usually put in about 5-7 KWH after a 20-25 mile run. (Our current electric power rate is $.05/KWH. Pretty cheap driving!) Later I will experiment with solar charging.
EV Miles
Start:135,100 Miles (217,375 Kilometers)
Current:135,220 Miles (217,568 Kilometers)
Total:120 Miles (193 Kilometers)
 
    As of 8/21/2007
Seating CapacityFour, however because of the increased weight, I try to limit back seat passengers ... very hard to do!
Curb Weight2,939 Pounds (1,335 Kilograms)
Left front: 851
Right front: 834
Left rear: 600
Right Rear: 654
(Measured with a Longacre "Accuset" Computer scales.)
TiresGoodyear Invicta
Conversion TimeI bought the car in 2004 and drove as a ICE. The conversion started in April 2007 and was substantially completed in August 2007. The parts were ordered in January 2007, however they didn't start arriving until April. VERY frustrating!
Conversion CostTotal cost: About $13,000, including the $900 I paid for the car. (The paint is as I bought it. Someone paid a lot of money for a beautiful deep purple job.) I put about $1,500 into suspension and steering repairs, including custom wound springs.
Additional FeaturesI have installed XM Satellite radio. The car had been previously lowered about 2" and I maintained that ... looks very "cool."
I love the car and the way it ended up. The performance is better than I expected with a 96-volt pack of 6-volt batteries. I think the larger Curtis controller and the new ImPulse 9 motor made the difference. Pulling 500 amps is a piece-of-cake, but I am careful not to exceed the 500 amp/2-min controller limit.

I discovered, after conversion, that the vacuum brake booster had a leak, causing the vacuum pump to short cycled ON/OFF. For now, I'm driving with no vacuum boost, but I have ordered a rebuilt booster, as new one's seem no longer to be available.

code by jerry