De ICEChevy Volt Battery PackWarp 9 InstalledAdapter Plate and Shaft CouplerRear batteriesAll cleaned updash
OwnerAlan Nasar
LocationEatontown, New Jersey US map
WebWebPage
Vehicle1971 Volkswagen Karmann Ghia Convertible
DC 180 volt system
using Chevy Volt battery pack broken into 4
sections. 2 batteries in the rear next to the
motor, 1 behind the rear seat and 1 in the
front trunk on top of the horn. No BMS.
MotorNetgain Warp 9 Series Wound DC
Series wound DC motor with advanced timing.
170 volts max.
DrivetrainStock 4 speed manual transaxle with reverse.
Used adapter plate and shaft coupler from
Wilderness EV which required additional
machining to install properly. No clutch.
ControllerSynkromotive DC 750
24-180 volts, 750 amps, fan cooled, digital
microprocessor controlled. No longer in
production, I purchased leftover inventory.
Batteries96, 3.70 Volt, Lithium-Ion
Complete 2013 Chevy volt Lithium Ion
battery pack. 96 modules total, 3.7 volts
& 45 ah each. 48 modules in series x 2 for
battery voltage of 178 volts. 16.5 kWh.
Configured as 4 separate 24 module blocks
80 lbs each block.
System Voltage180 Volts
ChargerElcon PFC 2000+
Synkromotive controller acts as charger.
Used
dell 12 volt 1200 watt power supply to
power charging mode. Couldn't get it to
work, using Elcon PFC 2000+. Time to full
charge at 115 VAC is about 10 hours.
Heaternone yet, thinking of seat heaters
DC/DC ConverterElcon TDC
Max Input Voltage Range: 108 - 216 volts DC
Output Current Range: 0-30 Amps at 12 volts
InstrumentationXantrex Lite with 10:1 passive prescaler
Top Speed90 MPH (144 KPH)
Still had room to go in 4th.
Should be good for about 100 mph. Stock top
speed is 86 mph.
Acceleration0-60 9.8 sec 8/29, 600 amps, 3rd gear.
0-60 run 13 sec on 8/12, controller
limited to
400
amps. Started in 2nd, shifted to 3rd.
Stock 0-60 is 21 sec.
Range60 Miles (96 Kilometers)
approximate, Have gone 40 miles wth voltage
starting at 197 dropping to 179. 55 miles
starting 197 dropping to 162.
Watt Hours/Mile260 Wh/Mile
Round trip including highways and city
average.
EV Miles
Start:82,720 Miles (133,096 Kilometers)
Current:84,056 Miles (135,246 Kilometers)
Total:1,336 Miles (2,149 Kilometers)
 
    As of 8/16/2018
Seating Capacity4 adults
Curb Weight2,000 Pounds (909 Kilograms)
Should be about 200 lbs over stock
TiresNankang CX668 165/80 R15
Additional FeaturesGigavac GC200-MA EV Contactor
Gigavac P105 Mini-Tactor Contactor Relay -
1200 VoltsFerraz A30QS500-4H - Ferraz Shawmut
500A 300VDC Fuse w/ Holder
Gigavac Maintenance Switch HBD41AA 1000V 400A
Continuous Hermetically Sealed (Main Switch)
WarP-Drive Hall-Effect Cable-Pull Throttle
WarP Motor Speed Sensor Kit
First drive 7/24/16. Almost burnt the
motor
because I forgot to take
tape off the cooling vents, luckily
realized
in
time. Drives well.
Still need to connect reverse lights and
brake
lights to controller.
Still need to connect charging circuit.
For
some reason, can't exceed
3600 rpm. Got it up to 45 mph.
7/28/16 Couldn't get the Synkromotive
controller to charge the
batteries so I ordered an ElCon PFC 2000+.
Ordered another fuse to
protect the front battery from short
circuit.
Still having RPM limit
issue. The rear end is a little low so I
ordered coil shocks for the rear.
Coil shocks installed 8/10, work great.
Rear
is at a normal height.
Elcon charger works nicely.
Got a tach and mounted in dash, disabled
controller RPM sensor.
Installed Custom Autosound replacement
stereo & speakers with subwoofer. Sounds
great.
9/13/16 Had some electrical problems,
blown
fuses, controller shutting down
intermittently. Traced to a short in the
reverse switch. Back in business.
11/11/16 Custom made 2x1 steel and
attached to floor pan from underneath to
stiffen chassis. Replaced front brakes
including disks, pads, and lines. Bought
rear brakes didn't install yet.
8/15/18 Installed high frequency battery
balancers and installed Elcon PFC 2500 up
front. Got new top, upholstry, paint.
Ditched Xantrex and got VDO voltmeter and
tachometer instead. Placed panel voltmeter
and ammeter hidden under dash. Car runs
great. Back window is original glass, leaks.

code by jerry