Rear Battery Boxes & CagesWhere the Beast Lives!TrunkTaming the Beast!My 2 Beetles
OwnerRoy Mann
LocationFreehold, New Jersey US map
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Vehicle1977 Volkswagen Super Beetle
Body off restoration and electrical conversion of a Convertible - My first Electric and a little different
than the last 3 Beetles I restored. This would be my 4th.
MotorD&D Motor Systems, Inc. ES-31B Series Wound DC
Too hot to keep your hand on it after 10 mile run at speeds up to 45 mph. I may enclose it and fan fresh air thu it to the passenger cabin....Hey! Free Heat!
Drivetrain4 speed manual trans - clutchless.
ControllerKelly 12600B
Programmable Bad Boy with 2 cooling fans & heat sinks.........Bit me twice!
Batteries15 Energizer GC8, 8.00 Volt, Lead-Acid, Flooded
Golf Cart Batteries Manufactured by Johnson Controls for Sam's Club - 63 pounds each. Hired a kid to load 'em.
System Voltage120 Volts
ChargerQuickcharge 120v - 10amp
Programmable On Board Charger with LED State of Charge reading.
HeaterYou're kidding right?
DC/DC Converter HWZ 120 -12 volt
only 300 watts - hoping its enough...might need two.
InstrumentationSimpson Amp & Volt gauges
Top Speed65 MPH (104 KPH)
Updated top speed: Still estimating 65 mph. I had the car up to 50 mph ( with one eye open) still some pedal left. After a few more recharges I will brave the Interstate.
AccelerationThe same as a stock Beetle.
RangeUpdated range: So far about 25 miles at 40 - 45 mph at 80% DOD if I can believe the state of charge reading on my Quick Charger. Have only driven the car about 120 miles since completion. Also hoping for more miles once I put a top on it. Stay tuned.
Seating Capacity2 Frightened Adults - both wondering if it would be better to be ejected in a crash or remain belted?
Curb Weight2,700 Pounds (1,227 Kilograms)
Just an estimate based on original curb weight of the vehicle less the engine, clutch, gas tank and back seat...plus the batteries, motor etc.
Tires4 at last count.
Conversion TimeThe Rust-Oration and welding on the frame took much more time than the actual installation of the Electrical System. Maybe 6 mos. total. Now it needs a top & paint. Hey! How about Green?
Conversion CostCar - $1500
Batteries, Motor, Controller etc. - $5500
Time away from wife....Priceless.
Additional FeaturesWelded Battery Cages front & rear. I don't want the rear 567 pounds of batteries to join me in the front seat.
Also, since the photos were taken I have replaced the Curtis PB6 Pot with a Kelly KP Series Throttle Pedal. It
eliminates the accelerator cable and places the pot right under it's own pedal next to the Brake Pedal. Fly by wire!
Comments: I welcome them. Email me - but before you suggest adding 19 Alternators or 3 Windmills please Google the term: "Perpetual Motion".
On board Solar Panels would help a little but not enough to offset the energy used while driving.
Also I forgot to add the restoration cost of the frame, suspension, brakes and interior. I did these myself to save on money. I will eventually paint the car myself and put on a new top so all that may add another $3000.00
Go Green! - Roy Mann

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