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David Carter's Electric Ghia Project
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Kmolenda
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PostPosted: Tue Sep 02, 2014 5:39 pm    Post subject: Reply with quote

Looking really good! If you get any farther post a few of the motor/trans combo. What it the gauge to the left of the speedo? And what's in the radio plate? I'm really itching to see this.
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dcat917
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PostPosted: Tue Sep 02, 2014 6:15 pm    Post subject: Reply with quote

Thanks Kmolenda, here are the details:

This a shot my dash for this project. From left to right, we have the voltmeter, speedometer (may be replaced with a Garmin), the motor controller display, and the state of charge meter. The state of charge meter is like a gas gauge. The unit to it's left puts out system error codes mainly. The voltmeter monitors the 12 volt Ghia systems health.

I will have a separate 144 volt 100Ahr electrical system to install that supports the motor that the 2 gauges on the right will be showing. I.m drawing that up now and trying to figure out where to put the components. These relays and switches are HUGE and connected by 2/0 cable.

I'll post photos of the motor installed later this week if all goes as planned.
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1981 Puma GTB http://www.thesamba.com/vw/forum/viewtopic.php?p=7794566#7794566
1971 Karmann Ghia http://www.thesamba.com/vw/forum/viewtopic.php?t=591290&highlight=
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Kmolenda
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PostPosted: Tue Sep 02, 2014 6:46 pm    Post subject: Reply with quote

That was my guess BSOC and the 12volt . Looks great. Does your Curtis provide a 12 volt output supply also or is that going to be a separate system all together? I know on the lifts we start with 36v (usually) jump to the AC component through the amps, then have a distribution of 24v , 12v and 5v outputs for running 12v computers, cameras or whatever they want to outfit it with. The only trouble I have run into is the AC component on some of the motors tends to real havoc on computer systems due to the isolation of the electrical system from the frame of the truck. Anyways, I wish I had the funds to do a project like this, your really doing a nice job, not only with the Ghia as a Ghia but looks like a really well thought out electrical setup. I've really enjoyed following your progress!
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swavananda
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PostPosted: Tue Sep 02, 2014 7:00 pm    Post subject: Reply with quote

dcat917 wrote:
Shooting for a 144 volt traction pack or about 42 cells, should give me 60 miles around town and support freeway speeds. Not going to be a cheap project but I should learn lots of new tricks on this one.

Great project,
Is that using 7-12V or 14-6V batteries? I read once that 6 V were better but the tech has been improving so much I don't know what's current. What is the life expectancy on the batteries these days? Also how long would it be to recharge after that 60 miles?Thanks.
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dcat917
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PostPosted: Thu Sep 04, 2014 11:55 am    Post subject: Reply with quote

The Traction Pack (drives the motor only) is made up of 3.2v cells in series. I'll have 42 of them which will give me a battery with 134V and 100AH. This should give me (aka Lead Foot) about 60 miles a day, which is plenty for my usage. Should be able to cruise at freeway speeds as well, but not going to be climbing any mountains with this battery.

Stay tuned, the motor is going in today Very Happy
Image may have been reduced in size. Click image to view fullscreen.

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1981 Puma GTB http://www.thesamba.com/vw/forum/viewtopic.php?p=7794566#7794566
1971 Karmann Ghia http://www.thesamba.com/vw/forum/viewtopic.php?t=591290&highlight=
Past Projects:
1951 Studebaker Business Coupe https://goo.gl/photos/eHPuNo89m9PXZwBM8
1953 Studebaker 2-Door Sedan https://goo.gl/photos/pe38HEShzUrVSwcV8
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dcat917
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PostPosted: Thu Sep 04, 2014 12:02 pm    Post subject: Reply with quote

Kmolenda wrote:
Does your Curtis provide a 12 volt output supply also or is that going to be a separate system all together?


Thanks Kmolenda, it's a separate system called a DC/DC Converter http://www.evwest.com/catalog/product_info.php?products_id=156

It feeds the auxiliary battery12V when running the motor by tapping into the high voltage on the traction pack.
_________________
1981 Puma GTB http://www.thesamba.com/vw/forum/viewtopic.php?p=7794566#7794566
1971 Karmann Ghia http://www.thesamba.com/vw/forum/viewtopic.php?t=591290&highlight=
Past Projects:
1951 Studebaker Business Coupe https://goo.gl/photos/eHPuNo89m9PXZwBM8
1953 Studebaker 2-Door Sedan https://goo.gl/photos/pe38HEShzUrVSwcV8
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dcat917
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PostPosted: Fri Sep 05, 2014 4:44 pm    Post subject: Reply with quote

I be doing the happy dance Very Happy Very Happy Very Happy . The motor is in and I have a clutch pedal now. Next I hook up the cooling system Which will pump anti-freeze through the chill plate for the motor controller.
Image may have been reduced in size. Click image to view fullscreen.


Video status on YouTube at

Link

_________________
1981 Puma GTB http://www.thesamba.com/vw/forum/viewtopic.php?p=7794566#7794566
1971 Karmann Ghia http://www.thesamba.com/vw/forum/viewtopic.php?t=591290&highlight=
Past Projects:
1951 Studebaker Business Coupe https://goo.gl/photos/eHPuNo89m9PXZwBM8
1953 Studebaker 2-Door Sedan https://goo.gl/photos/pe38HEShzUrVSwcV8
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dubulup
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PostPosted: Fri Sep 05, 2014 8:15 pm    Post subject: Reply with quote

I'm loving this this project! Super clean work...and nice MB. Any plans for the torsion bars with all the added weight?
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Kmolenda
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PostPosted: Sat Sep 06, 2014 7:19 am    Post subject: Reply with quote

Great walk through ! She's a real beauty, I am impressed. Can't wait to see this run.
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Clatter
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PostPosted: Sat Sep 06, 2014 8:13 am    Post subject: Reply with quote

Sweet project!
I'm digging the whole thing.

Looking at your interior shot here:
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The digital gauges and all that clean silver bare metal go together.
Don't finish it all out in fluffy carpet and poofy padded vinyl or cloth.
Leave it all clean silver metal and you have some type of high technology clean-room industrio theme perfect for the powerplant retro-fit you have going on!
Very Happy Very Happy

Plus, you don't need the sound insulation, because it will be quiet,
And the weight savings will help both mileage and performance..!
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dcat917
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PostPosted: Sat Sep 06, 2014 8:39 am    Post subject: Reply with quote

We think alike Clatter, here's what I'm doing for carpet. Still have not decided what to do with the tunnel but I have stripped all the old tar paper off and am leaning toward the silve mat used on the kickpanels
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_________________
1981 Puma GTB http://www.thesamba.com/vw/forum/viewtopic.php?p=7794566#7794566
1971 Karmann Ghia http://www.thesamba.com/vw/forum/viewtopic.php?t=591290&highlight=
Past Projects:
1951 Studebaker Business Coupe https://goo.gl/photos/eHPuNo89m9PXZwBM8
1953 Studebaker 2-Door Sedan https://goo.gl/photos/pe38HEShzUrVSwcV8
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dcat917
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PostPosted: Sat Sep 06, 2014 10:45 am    Post subject: Reply with quote

dubulup wrote:
I'm loving this this project! Super clean work...and nice MB. Any plans for the torsion bars with all the added weight?


Already have the front bar installed and have the rear bar ready to go on after I have the torsion bars adjusted. link to rear-> https://www.jbugs.com/product/9610.html
_________________
1981 Puma GTB http://www.thesamba.com/vw/forum/viewtopic.php?p=7794566#7794566
1971 Karmann Ghia http://www.thesamba.com/vw/forum/viewtopic.php?t=591290&highlight=
Past Projects:
1951 Studebaker Business Coupe https://goo.gl/photos/eHPuNo89m9PXZwBM8
1953 Studebaker 2-Door Sedan https://goo.gl/photos/pe38HEShzUrVSwcV8
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dcat917
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PostPosted: Tue Sep 16, 2014 5:31 pm    Post subject: Reply with quote

I now have the cooling system working and getting ready to tackle the throttle linkage next. Here's a video of the project. I wish the cooler was more quiet. Confused

http://youtu.be/lW4sFtgY6tY

Image may have been reduced in size. Click image to view fullscreen.


Image may have been reduced in size. Click image to view fullscreen.

_________________
1981 Puma GTB http://www.thesamba.com/vw/forum/viewtopic.php?p=7794566#7794566
1971 Karmann Ghia http://www.thesamba.com/vw/forum/viewtopic.php?t=591290&highlight=
Past Projects:
1951 Studebaker Business Coupe https://goo.gl/photos/eHPuNo89m9PXZwBM8
1953 Studebaker 2-Door Sedan https://goo.gl/photos/pe38HEShzUrVSwcV8
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Kmolenda
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PostPosted: Tue Sep 16, 2014 5:39 pm    Post subject: Reply with quote

I have a feeling your going to be stopping for a lot of bathroom breaks listening to the pump noise, lol. The fan is quite loud, I suppose you could find a quieter one. Looking great. What's an eta on a first test run?
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dcat917
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PostPosted: Tue Sep 16, 2014 8:06 pm    Post subject: Reply with quote

I hope to have it completed by Christmas this year. Need to build up my bank account before purchasing the batteries Laughing I still have to restore both the doors and fit them before being road legal but I see a few small test runs around the block before that happens.
_________________
1981 Puma GTB http://www.thesamba.com/vw/forum/viewtopic.php?p=7794566#7794566
1971 Karmann Ghia http://www.thesamba.com/vw/forum/viewtopic.php?t=591290&highlight=
Past Projects:
1951 Studebaker Business Coupe https://goo.gl/photos/eHPuNo89m9PXZwBM8
1953 Studebaker 2-Door Sedan https://goo.gl/photos/pe38HEShzUrVSwcV8
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KGCoupe
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PostPosted: Thu Sep 18, 2014 6:46 am    Post subject: Reply with quote

Just curious - will that coolant get hot enough to need a pressure relief cap on the reservoir similar to the cap used on a standard water cooled automobile radiator?

I can't tell from the picture/video if the cap on there is a pressure relief style or not.

Another thing I'm curious about - if you wanted to run an air conditioning system with a vehicle that has been converted to electric drive, how would the compressor be driven?
Obviously modern electric vehicles must have a system made specifically for that application, but I imagine they would be pricey.
(... as opposed to the inexpensive portions of the electic drive conversion such as the motor and batteries Smile )
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dcat917
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PostPosted: Thu Sep 18, 2014 2:38 pm    Post subject: Reply with quote

KGCoupe wrote:
Just curious - will that coolant get hot enough to need a pressure relief cap on the reservoir similar to the cap used on a standard water cooled automobile radiator?

I can't tell from the picture/video if the cap on there is a pressure relief style or not.

Another thing I'm curious about - if you wanted to run an air conditioning system with a vehicle that has been converted to electric drive, how would the compressor be driven?
Obviously modern electric vehicles must have a system made specifically for that application, but I imagine they would be pricey.
(... as opposed to the inexpensive portions of the electic drive conversion such as the motor and batteries Smile )


The system has a sealed non-venting cap now. I might swap it for a vented one later. As far as AC. they make a bracket for that.http://www.evwest.com/catalog/product_info.php?products_id=184
_________________
1981 Puma GTB http://www.thesamba.com/vw/forum/viewtopic.php?p=7794566#7794566
1971 Karmann Ghia http://www.thesamba.com/vw/forum/viewtopic.php?t=591290&highlight=
Past Projects:
1951 Studebaker Business Coupe https://goo.gl/photos/eHPuNo89m9PXZwBM8
1953 Studebaker 2-Door Sedan https://goo.gl/photos/pe38HEShzUrVSwcV8
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Kmolenda
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PostPosted: Thu Sep 18, 2014 4:30 pm    Post subject: Reply with quote

The AC system I saw installed in another electric VW was driven by another 24v dc motor up front, the guy did a great job, but it was a 24v dc drive too. No where near as cool as this build.
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dubulup
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PostPosted: Thu Oct 16, 2014 8:46 pm    Post subject: Reply with quote

I need some updates...I drove a Model S (again) and caught the fever all over
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didget69
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PostPosted: Fri Oct 17, 2014 8:18 am    Post subject: Reply with quote

KGCoupe wrote:

Another thing I'm curious about - if you wanted to run an air conditioning system with a vehicle that has been converted to electric drive, how would the compressor be driven?
Obviously modern electric vehicles must have a system made specifically for that application, but I imagine they would be pricey.
(... as opposed to the inexpensive portions of the electic drive conversion such as the motor and batteries Smile )


Some motors have a double-ended shaft setup that has the shaft opposite from the transmission end projecting out (as it would on a standard Aircooled VW engine. A pulley is attached to this, and the A/C compressor is driven by belt from this pulley, similar to any gasoline powered car. Shaft can be used to drive alternator, hydraulic pump for power steering, A/C compressor, etc.

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bnc
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