OwnerMarc Hult
LocationCovington, Kentucky US map
Web/EmailWebPage email image
Vehicle1967 Volkswagen Beetle
To be 'unveiled' summer 2009.
The rust-free donor from Arizona has almost entirely original body.
MotorAdvanced DC XP-2197 variant of 203-60-4001a Series Wound DC
has slight differences from -4001a in shaft geometries and perhaps other parameters. It has both brush and coil thermocouples and a temperature switch. The motor was originally used (~600 miles) in a NetGain Motors EMIS (Engine Motor Interface System) installation.
DrivetrainA motor/clutch adapter has been received from Electro Automotive. It will be used with a lightened, gearless flywheel purchased through www.thesamba.com
ControllerKelly KDH14500 144v 500A series/PM
Didn't have the patience to wait for a Zilla and so settled for a Kelly. We'll see ...
Batteries12 Energizer GC8, 8.00 Volt, Lead-Acid, Flooded
This matched set was manufactured in Mexico for/by Johnson Controls in January 2008 and purchased February 2008 for $67 each. I have 24, 50-watt 48-vdc silicone heater pads with built-in thermistors.
System Voltage96 Volts
ChargerSchauer Two JAC1548 's (similar to KIPOINT KI-2048A )
Chargers are on-board and auto-switch between one charger when plugged into 110VAC and two chargers when plugged into 220VAC. This allows for opportunity charging with typical 110VAC 15 amp circuits as well as dedicated 220VAC charging at home. Long-term plan is to also add solar to home's roof. I have a Morningstar TriStar TS-45 45-amp charger for that purpose. The system is designed to accommodate triple 48v banks should I migrate to a 144v system and to serve as power source for the home during outages.
HeaterNone yet. Accumulated parts for peltier-based air conditioner two decades ago.
DC/DC ConverterVicor 3 x 250-watt 48v input VICOR half-bricks
Two are connected (one to each 48v battery bank) with a third installed but not connected for possible upgrade to 144v system., DIN rail circuit breakers on input and outputs. Also Vicor Ripple Attenuation Modules (RAM)
InstrumentationSix simultaneous blue LCD displays of DC-DC output and standby battery voltages, traction battery and motor current, and traction battery and motor voltage. When the car is being charged, the traction battery and motor displays switch to charger current and voltage. Type J thermocouples on brushes and coils. Will add tachometer to rear motor shaft. Have mini-itx PC with National Instruments Data Acquisition Card. I may migrate ELK MM443s microcontrollers, 1-wire I-Button inputs and software from home automation system to the E-Bug.
Top SpeedNot yet operational
Seating CapacityNo change from original 2 + 2. However the added weight of passengers would exceed GVWR.

A pair of heated, motorized, black leather front seats from 2003 VW Passat were purchased through eBay for $200. Their added weight and built-in airbags complicate matters and a different solution for the safety need of head retraints may be needed.
Curb Weight2,500 Pounds (1,136 Kilograms)
Objective is to stay within GVWR of 2600 lbs carrying the driver and groceries.
Tires165-15 radials on vented OEM VW 1967-only 5-bolt rims.
Conversion Time"All done but the doing."
Conversion Cost"Bout a hundred dollars"

Our home (see www.danbeard.com ) is within view of where parts of 'Rain Man' were filmed in 1988.
Our only family car in the 1950-70's were (in order) 1956, 1961, 1965 and 1963 Beetles. So the glider donor is a nostalgic blast from the past for us. IMO, 1967 was the last year that the VW type I looked like an 'old' Beetle and was 'best' from a variety of perspectives. It is not optimum for EV conversion but can be made safe(r) with new seats, proper NEDRA-compliant battery restraints and boxes among other requirements. A Karman Ghia would be better choice for conversion owiung to lower (Cd x A) and better battery placement and was considered, but the personal connection isn't there.

The 7.6-mile (round-trip) daily commute on city streets features two-mile 5% grade in the morning. This will be a major test. Morning rush-hour traffic can be aggressive and often exceeds the posted 30 mph speed limit. Can/should the E-Bug ? ;-)

code by jerry