|Location||Freehold, New Jersey US map|
|Vehicle||1977 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.
|Motor||D&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.
Will add a ducted 12v cooling fan to the motor.
|Drivetrain||4 speed manual trans - clutchless.|
Have sheared the teeth in 2 clutch hubs
which were welded to the LoveJoy Tube that connects the motor to the trans.
Hint: Don't floor it on takeoff.
|Controller||Kelly 12600B |
Programmable Bad Boy with 2 cooling fans & heat sinks.........Bit me twice!
|Batteries||15 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.
Ordered 40 TS 160AH Thunder Sky Lithiums to replace the Lead Pack....stay tuned.
|System Voltage||120 Volts|
|Charger||Quick Charge 120v - 10amp|
Programmable On Board Charger with LED State of Charge reading.
|Heater||Innovative Heated seat pads installed under the vinyl. 12v Hi-Low-Off lighted controls. 60 watts each seat.|
|DC/DC Converter|| HWZ 120 -12 volt|
|Instrumentation||Simpson Amp & Volt gauges.|
Recently purchased a Link 10 Meter. Will install with the new Lithiums.
|Top Speed||65 MPH (104 KPH)|
With one eye open and cringing I braved the Interstate and had the car up to 61mph. Hoping to increase that a little once I put a top on the car.
|Acceleration||The same as a stock Beetle.|
|Range||38 Miles (61 Kilometers)|
Updated range: 36-38 miles at 40 mph at 80% DOD if I can believe the state of charge reading on my Quick Charger. Have only driven the car about 1500 miles since completion.
|Seating Capacity||2 Frightened Adults - both wondering if it would be better to be ejected in a crash or remain belted?|
|Curb Weight||2,700 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.
|Conversion Time||The restoration and welding on the frame took much more time than the actual installation of the Electrical System. Maybe 6 mos. total.|
|Conversion Cost||Car - $1500|
Batteries, Motor, Controller etc. - $5500...$8000 for the Lithiums soon to be installed.
Time away from work....Priceless.
|Additional Features||April 2010|
Installed new top, padding, cables and headliner.
Dec. 09 Update -
Ordered 40 Thunder Sky Lithium Batteries 160Ah each. Will install 38 of them in the Beetle after I have culled out the weakest 2. This helps better balance the pack against low discharge and over charge damage. Also gives me 2 spares in the event of mechanical failure or accidental damage. 10 years from now I might not be able to purchase a cell which matches this chemistry. These new TS Cells LiFeYPo are rated at 3000 recharges at 80% DOD....they could possibly last me 15-20 years.
Aug 09 Update -
Completely stripped and repainted the car Base Coat, Clear Coat - Metallic Beige. Currently re-upholstering the seats. Added Innovative Seat Heaters under the new vinyl- only 60 watts each.
Welded 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!
Jan. 09 - Upgraded the front brakes from stock drum to disc. Significant improvement in stopping distance.
|Comments: I welcome them. Email me - but before you suggest adding 19 Alternators or 3 Windmills please Google the term: "Perpetual Motion" or "Over Unity". |
On board Solar Panels would help a little but not enough to offset the energy used while driving.
Also forgot to add the restoration cost of the frame, suspension, brakes, interior, top and paint. I did these myself. Add another $3500.00
Drive Green! - Roy