Motor and Adapter PlateTransmission BellhousingGoodrum/Fecther LiFePO4 BMS KitMotor, adapter and mounting.Dash Board DismantledHW 38120S Battery CellsA single 38120S cell.76.8 Volt, 50 AHr Pack Load TestThe 76.8 Volt, 50 AHr pack, Assembled
OwnerAdam E. Hampton
LocationHouston, Texas US map
Web/EmailWebPage email image
Vehicle1990 Volkswagen Cabriolet
2 Door, 5 seater.
MotorNetgain Impulse9 Series Wound DC
NetGain Impulse9 motor, 129lbs. Adapted
to the VW transmission using Steve
Clunn's (GrassRoots EV) adapter plate
kit.
Drivetrain5 speed manual transmission, clutch-less
coupling to the DC motor.
ControllerCurtis 1231C
Curtis 1231C Controller with Curtis PB-5
potbox. 500A peak. Starting off I am
going to in-controller limit that to
around 200A to accommodate my
experimental batteries.
Batteries96 Headway 38120S LiFePO4 (Lithium Iron Phsophate), 3.20 Volt, Lithium-Ion
This is a custom-built battery pack that
I am making. The first version will be
72v, 50amp-hour. It consists of 120
LiFePO4 cells manufactured by the
Chinese vendor Headway. 3.2v, 10-amp-
hour, 38mm x 120mm cylindrical cells
with screw tabbed end caps, arranged in
a ((5p)x24s) configuration. Managed by
the Goodrum/Fechter BMS kit available at
tppacks.com and documented at endless-
sphere.com in the forums.
System Voltage77 Volts
ChargerZivan NG-3
The one I have is currently programmed
for 120V flooded lead acid. I will see
if Zivan will re-program it for me to
88.8 CC/CV Sealed Lead Acid profile for
use with my LiFePO4 cells and my BMS.
HeaterNone currently.
EV Miles
Start:223,762 Miles (360,033 Kilometers)
Seating Capacity5 adults
Conversion TimeStarted July, 2008. Very much a "spare
time" hobby.
Conversion CostDonor Car: $550.00
Controller/Charger/Wires/Shunt/Contactor
/Old motor: $2500
NetGain Impulse9 Motor: $1575.00
Battery Management Systems: $200.00
Battery Cells (72Vx50AHr): $2062.50
... more to come.
May 4, 2009: Initial post to evalbum.com. The car is in
progress, lots of information to post. Status at this
point:
- Pressure washed engine compartment, still oily as all
get out because the ICE leaked oil badly.
- ICE motor removed. Vacuum lines and power steering
assemblies left in tact as much as possible.
- Exhaust system removed.
- Fuel pumps and fuel lines removed.
- Gas Tank siphoned and water-rinsed for removal.
- Gas Plug/Cap replaced with 120VAC male plug end.
- Sheilded GFCI outlet and 120VAC wiring installed in
trunk.
- Installed new shift-linkage connections and bearings to
replace worn components.


May 9, 2009: A couple of updates.
- Goodrum/Fechter BMS Boards are fully assembled and
tested.
- Batteries ordered from overseas with a group buy!
- Gas tank removed (had to drop the rear suspension).

June 4, 2009:
- Corrected the model of my charger.
- Contacted ZivanUsa.com to see about supporting an
LiFePO4 profile on my charger.

June 8 2009:
- Shipped the charger off to Zivan for a new firmware
load.
- Machined aluminum mounting plate for passenger side of
the Netgain Impulse 9 Motor. (Thanks, Bill!)
- Attached motor and adapter plate to transmission.
- Leveled motor and drilled level-holes for mounting
plate.
- Purchased new bolts for mounting plate side, will
install later this week.

June 9, 2009:
- Finished installing and leveling passenger side motor
mounting plate.
- DROVE UNDER BATTERY POWER FOR FIRST TIME! Only about 10
feet in the driveway, but it worked!


June 16, 2009:
- Installed the last engine mount adapters up against the
front bumper. This required grinding about an inch off
the front of the adapter plate so the slanted mounting
brace would fit in.
- Zivan USA is shipping my reprogrammed NG3 charger back
from servicing. It is now configured to match the
charging curve on my Headway cells and it will interact
with the cutoff logic of my battery management system
boards.


June 23, 2009:
- Zivan charger is back from reprogramming.
- Battery cells were confirmed on the boat from China on
6/20.
- Started dissecting the steering column and dashboard.
Got to remove the heater coils and cleanup some shoddy
wiring the previous owner put into the car. Managed to
remove the airbag without exploding myself.

August 30, 2009:
- Steering column repaired and replaced.
- Built replacement power window controller (original was
shot).
- Battery cells have arrived (see pictures).
- Starting to lay out battery cells and design first
revision pack.

code by jerry