motor in standmotor & tranny in fixturedropping inback emblemsEngine compartmentCeramic heaterDash removed
OwnerChris Freyman
LocationMacungie, Pennsylvania US map
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Vehicle1983 Volkswagen Rabbit Convertible
MotorAdvanced DC FB1-4001A Series Wound DC
9", 143lbs
DrivetrainClutchless 5-speed transmission. Homemade adapter plate using ½” 6061 aluminum. Coupler courtesy Brian @TanicEV.
Controller Revolt 144V-500A
Design based on Paul Holmes’s ReVolt open source controller. It controls main contactor, so I’m adding interlock capability for e-brake and charger detect. Also will add isolated pack measurement module to tie in. The controller will then serially output amps, volts, temp to my instrumentation package. This is my winter project.
Batteries10 Unknown, 12.00 Volt, Lead-Acid, Flooded
Either Everstart 27DC-6, Crown 31DC36 or DEKA DC31DT.
Deka plant is not too far from me and I hear you can get up to 50% off on factory seconds. Trying to keep costs down to get this project on the road
System Voltage120 Volts
Charger Homemade
Will be a smart charger based on PIC microcontroller. Input 110VAC w/ output charge current in 8A range. Boost input, then DC rectified and phase controlled with SCR to deliver controlled charge current. This will be my second winter project!
HeaterCeramic from 1500W portable AC unit
DC/DC ConverterIota DLS-30
InstrumentationHomemade. PIC controlled unit receives serial info from controller (volts, amps, controller temp). Direct A/D inputs will also monitor motor temp, 12V accessory voltage, ambient temp. Output to 3 displays. Display #1 will be 4 digit green led (Volts), display #2 will be 4 digit red led (amps). Display 3 is 10 segment bar graph to display SOC of batteries. Will have single button to cycle 4 digit displays for- (1) volts/amps, (2) motor temp/controller temp (3) 12V batt/ ambient temp.
Top Speed76 MPH (122 KPH)
Has the FN type 5-speed transmission which has lower gear ratios for higher speed.
AccelerationExpect it to be peppy with 9" motor and only around 700lbs of lead
Range25 Miles (40 Kilometers)
Expect to get around 25 miles per charge. Not enough for my 50 mile daily work commute (each way), but good enough for weekends or my wife’s errands around home.
EV Miles
Start:74,148 Miles (119,304 Kilometers)
Current:74,148 Miles (119,304 Kilometers)
Total:0 Miles (0 Kilometers)
Seating Capacity4 Adults
TiresBought it with low profile 205/40/R16's. Look's cool, but will probably replace with stock to get better efficiency.
Conversion TimeSince this is a conversion mixed with restoration, total time would be misleading. Not keeping track. Goal is to have this on the road by early next summer though. Long hours at work leaves this as mostly a weekend project.
Conversion CostDonor Car (shell) $675 + $1,000 in replaced parts= $1,675
EV Components:
Motor- $1,330 (includes freight)
Batteries- $800 (estimate)
Adapter plate- $46
Motor coupler- $158
Tyco Contactor- $61
(2) 500A Fuses- $10
Thomas 107DC20 pump- $75
Vacuum switch- $29
IOTA DLS-30- $35
Controller- $150 (estimate)
Charger $100 (estimate)
Instrumentation- ($65) estimate
2/0 welding cable – ($85)
Terminals & other random parts- $85
Total EV stuff= $3,000

Pretty much all EV components found on Ebay. Great way to save money. Motor, contactor & vacuum switch were brand new, the rest used. Car replacement parts were a mix of Ebay and “The Samba” (VW enthusiasts website).
Had a $4,500 budget which I’ll probably exceed, but not by much. Car selection based on being a lightweight convertible (fun factor), with as little rust as possible. Found a great shell, but it was a mixed bag.
The Good- The ICE was already gone, car was 98% rust free, and it had recent paint job (cool Chevy tangerine pearlcoat)
The Bad- Passenger door damaged and had to be replaced, ALL wiring harnesses removed and stuffed in a box, MANY missing parts (tranny mounts, linkage, side marker lights, badges, interior plastics, interior carpeting)

June 09- Removed gas tank & fuel delivery system. Degreased engine bay and transmission. Repainted transmission, brake booster, master cylinder. Replaced rotors & pads. Replaced passenger door with junkyard find.

July 09- Replaced front wheel bearings. Clean & repack CV joints & replaced cracked boots. Created motor adapter plate (slow process with 4” hole saw and hack saw!).

Aug-09- Installed adapter plate to motor & added coupler. Build wooden fixture to hold motor vertically, then dropped tranny onto it. Alignment process suggested by Brian at TanicEV. Basically involves lightly clamping bell housing to motor plate, then run motor to “self align” to tranny before marking bolt holes and installing alignment pins. Result= vibration free alignment. Install motor & transmission into engine bay and attached axles.
Build a few 2/0 cables to attach to motor. Cables temporarily run into passenger compartment to attach to one 12V battery (via jumper cables) in passenger seat.
Aug-22 maiden voyage down driveway & back.

Sept 09- Reinstalled some backseat plastics and driver’s side doorcard & mirror. Performed bodywork on rear driver side fender. Wetsand passenger door and primered in preparation for paint & clearcoat. Installed side marker lights & exterior trim. Turned my attention to reinstalling the wire harnesses. Took opportunity to remove wires associated with ICE sensors & such. Some melted wires needed to be replaced. Replaced headlight switch (melted in “on” position).

Oct 09- Paint & clearcoated passenger door. Reinstalled passenger doorcard & mirror. Installed DC-DC converter and accessory battery. Resinstalled all remaining wire harnesses & fuse box. Added additional wiring in support of EV instrumentation, controller interlocks, etc. Reinstalled dashboard and blower assy. Reworked heater core with ceramic heater.

code by jerry