Electric BajaMotor/controllerMotor/controllerDashboard w/ InstrumentsLithium Battery PackCharger and DC/DC ConverterBattery Box with LED Cooling Fans
OwnerJonathan Barraclough
LocationTehachapi, California United States map
Vehicle1965 Volkswagen Bug
It's a 1965 Baja Bug. Had some rust damage when purchased, but took care of it. After the paint job it looks awesome!
Motor AC-30 3-Phase AC
DrivetrainOriginal 4-speed transaxle with clutch (only use 2nd, 3rd, 4th, and reverse).
ControllerCurtis 1238-6501
Curtis 1238, 3-phase AC induction w/ regenerative braking, 550A peak, 15 lbs.
Batteries20 Kokam SLPB 78216216H, 3.70 Volt, Lithium-Polymer
Kokam lithium-polymer; 74V 93Ah (20s3p); 120 lbs; 930 Amps peak, 465 Amps continuous; 1200 cycles to 80% of initial capacity.
System Voltage74 Volts
ChargerZivan NG1
Zivan NG1; 10A, 1KW; 115VAC input; programmed for lithium batteries.
DC/DC ConverterVicor VI-M4P-EQ
400W; 72V to 13.5V
Instrumentationo BMS: 2-line digital LCD; pack current, max cell temperature, max cell voltage, min cell voltage, Ah remaining.
o BMS: Palm IIIxe; all cell voltages, all cell temperatures, nominal pack Ah, Ah remaining, pack current, status codes, error codes.
o Spyglass (motor/controller): motor RPM, discharge/charge current, pack voltage, motor temperature, controller temperature, LED efficiency readout, regen indicator, error codes.
o 12V accessory battery voltmeter
o Speedometer
Top Speed65 MPH (104 KPH)
Top speed is had in 4th gear.
AccelerationAcceleration is very good in 2nd and 3rd gear. Tapers off the faster you go.
Range40 Miles (64 Kilometers)
Best range is in-town driving where top speed is about 45mph. Going 65mph cuts that in half.
Watt Hours/Mile200 Wh/Mile
Setting up to do better data capture during driving to ascertain the exact numbers.
Seating CapacitySeats 4 adults
Curb Weight0
Unknown at this time. The gas engine I took off weighed about 200lbs. The batteries are 120 lbs, motor 85 lbs, controller 15 lbs, so it's about the same weight as the gas version with a full tank of gas.
Conversion TimeI built it over the course of about a year, working nights and Saturdays when I could.
Conversion Costbody cost $2700 (sold the engine for $850)
motor/controller kit = $3900
Adapter plate / shaft coupler = $900
batteries = free (but worth about $6000)
charger = $600
DC/DC = $350
BMS = $2300
Body work and paint job = $2000
Additional FeaturesThe AC drive system with regen braking is really sweet. The added benefit of a light lithium battery pack makes this car really spritely off the line and drives like a race car. The motor/controller kit came with a Spyglass multipurpose meter that gives you a real-time LED indicator of efficiency, which I use as feed back to better control my current draw (much like the efficiency meter on some hybrids). The BMS and Curtis controller protect against all situations that could damage the components, so I feel really safe driving it around.

code by jerry