T2 VW bus convert to EV

[79 EV VW]

This thread is to share my experience converting a VW bus to plug-in electric. I was inspired to write because of CJ7guy1's excellent documentation on converting his 1984 CJ7. I have some limited EV conversion experience helping my son convert a 50year old jeep to EV. I am not a VW guy, so I learned a lot from this forum before I started.

When I turned 17 years old I got to drive a rotted-out VW bus for the summer. What a blast! It would only go 45 mph on the flat and 50 mph on a downhill, but it was open with no sliding door. Basically you just drove it full throttle all the time.

That decided me on a basic VW for donor car, to bring back my youth. I needed a stick-shift to make the conversion to electric simple. I wanted manual steering for simplicity: I did not need an electric power steering pump. I did not know that all old VWs had manual steering. Buses had good suspension for their weight, so the bus could carry a lot of batteries with no problem. (Well, except for stopping with manual drum brakes and lots of battery weight.) And lastly, lots of EV and repare parts were available for older VWs. Try getting parts for a 1969 ford sedan. The practical reasons were my wife had a beetle 35 years ago, and she loved it, so she gave me an OK for a VW EV car.

My plan for the EV bus:

*This was for an around the town errand car

* I wanted a bus to save from destruction

* I only needed around 100 mile range, because it was an errand car, not a drive-to-Las Vegas car. Of course more range was better.

* I planned to use well known motors, controllers, battery chargers, and motor adaptors. When I got in trouble, I wanted to advice from people who knew what they were doing. Lesson learned

* I want to use lithium ferro phosphate batteries, not recycled Tesla batteries. Easier to install (no water cooling) and safer. 30K-watt hours should give 100 mile range in a VW, based on my jeep experience

In April 2024 I found a bus that met my criteria in Atascadero, CA. This was a 1979 type-2 bay window with no engine

The bus had been stored in a barn since 2010. The previous owner was converting it to plug-in electric, but he got sick and died before he could finish. This bus had a DC electric motor installed to the transmission, and came with a motor controller.

The frame was solid and the body looked good, until you looked more closely than a photograph. 4-speed stick and wires hanging out of the dash. Perfect.

Next post I will share some of the issues getting this clunker ready for EV conversion.

[aeromech]

Dumb question but what does the DMV say?
_________________
Lead Mechanic: San Diego Air and Space Museum
Licensed Airframe and Powerplant Mechanic
Licensed Pilot (Single engine Land)
Boeing 727,737-200-300-400,757,767
Airbus A319,320,321
DC9/MD80
BAe146
Fokker F28/F100
VW type 1 1962,63,65,69,72
VW Type 2 1971 (3 ea.) 1978, 1969
VW Jetta
VW Passat
Capable of leaping tall buildings in a single bound

[79 EV VW]

The DMV does not know yet and I am afraid to ask. Two problems with the DMV

1. the 'pink slip' title is out of date. The previous owner, #2, now dead, had the title signed over to him when he bought the bus from the origirnal owner, #1. However #2 never bothered to get a new title. I have that sigmed pink slip and a bill of sale from the barn/storage owner, a friend of owner #2

2. After I get a clear title, I have the problem of registering the VW as an EV. The issue is that the VW has to go through smog inspection to get new registration/plates. A smog inspection station can not pass the EV because it does not match the engine on the serial number. (vehicles older than 1975 do not have to get a smog inspection, the drive train is not important) The DMV does not have a system to register reworked vehicles, even though there is a law that all vehicles must be electric by 2035. My understanding is that you must get DMV supervisor to meet with a DMV smog referee to certify that the vehicle is truly an EV. That means you have to tow the EV to the referee for the inspection. The inspection includes a safety check of all lights, brake wear, seat belts, tires and mechanical condition, as well as 0 emissions. After the vehicle passes the inspection, you can get a new title as an EV.

[lil-jinx]

sounds like it would be simpler to just fine an older bus.ans avoid the smog certification
_________________
https://www.thesamba.com/vw/forum/viewtopic.php?t=620186
https://www.thesamba.com/vw/forum/viewtopic.php?t=668799
1974 Bay Westfalia. she likes to be called Ethel.
1968 Dune Buggy sold dec 2024

1974 parts bus
A smart man learns from his mistakes,a very smart man learns from other's mistakes.

[aeromech]

How much do the batteries weigh?
_________________
Lead Mechanic: San Diego Air and Space Museum
Licensed Airframe and Powerplant Mechanic
Licensed Pilot (Single engine Land)
Boeing 727,737-200-300-400,757,767
Airbus A319,320,321
DC9/MD80
BAe146
Fokker F28/F100
VW type 1 1962,63,65,69,72
VW Type 2 1971 (3 ea.) 1978, 1969
VW Jetta
VW Passat
Capable of leaping tall buildings in a single bound

[airschooled]

Get the title first!

Then you make an appointment when the swap is done. You drive it to the inspection station. They check a box, you pay the fee, and you now have a legal registered vehicle that never needs smog tests again. It’s much simpler than dealing with a lost or missing title.

Good luck! You’re at least number six on here going for the conversion… none have reported back with running and driving cars, but I like to think that’s because of the attitudes here and not because it’s an absolutely monumental process that is going to test the limits of your creativity and technical abilities.

Robbie
_________________
WTB: 215mm Type 4 flywheel. Cash in hand.

One-on-one tech help for your vintage Volkswagen:
www.airschooled.com

Road trip reports and tech blog:
https://www.patreon.com/airschooled

[70bus]

I saw one that runs and drives (owner says he has had it on freeway).

Tesla batts, EVWest parts. It can and has been done... but don't spend money on a bus you don't have clear ownership of!
_________________
Craig K
70 Neunsitzer
65 Pritschenwagen
"If Von Dutch was alive, he'd walk in there with a pistol and shoot these people." - Robert Williams

Raoul the 65 singlecab

Karl the 70 nine-seater

[airschooled]

That battery box over the engine design scares the shit out of me. MUCH safer and better handling if you build a false floor and keep the center of mass lower and more centered. It’s a cool idea in a magazine but I won’t ride in them anymore.

Robbie
_________________
WTB: 215mm Type 4 flywheel. Cash in hand.

One-on-one tech help for your vintage Volkswagen:
www.airschooled.com

Road trip reports and tech blog:
https://www.patreon.com/airschooled

[70bus]

Agree on C.O.G. The OG VW electric van attempts in 70s had the batteries on the cargo floor. One reason I restored my singlecab is the ability to put a crapload of batteries in the treasure chest should I wish to convert.
_________________
Craig K
70 Neunsitzer
65 Pritschenwagen
"If Von Dutch was alive, he'd walk in there with a pistol and shoot these people." - Robert Williams

Raoul the 65 singlecab

Karl the 70 nine-seater

[aeromech]

Still waiting on an answer regarding battery weight?

I’ve driven buses loaded down with scuba tanks, outboard engines, etc. you get the idea. It’s okay for a trip but when buses get very heavy they steer like shit. I really don’t know. Maybe the conversion isn’t too heavy.
_________________
Lead Mechanic: San Diego Air and Space Museum
Licensed Airframe and Powerplant Mechanic
Licensed Pilot (Single engine Land)
Boeing 727,737-200-300-400,757,767
Airbus A319,320,321
DC9/MD80
BAe146
Fokker F28/F100
VW type 1 1962,63,65,69,72
VW Type 2 1971 (3 ea.) 1978, 1969
VW Jetta
VW Passat
Capable of leaping tall buildings in a single bound

[airschooled]

[Abscate]

The weight distribution in real climate areas like the Northeast is even more critical. Once a skid starts with a big plug of weight in a non-designed place, it’s over.
_________________
🇺🇸 🇺🇸 🇺🇸 🇺🇸 🇺🇸 🇺🇸 🇺🇸 🍊 🍊 🍊

[jjvincent]

If I was doing it, I'd put three battery packs under the center section of the floor. It's literally the perfect place for them as you don't need the stove pipe for heat. Then you could put another battery pack above the motor while you are at it.

I seen a guy that took a 912 and did an EV conversion to it. One thing that I liked was he eliminated the transmission (it didn't come with one). So, the transmission was replaced with a 9" Ford rear end. Reverse cut ring and pinion. Tubes cut off, flanges attached and those ran to the axles. Simple and opened up lots of room for whatever other controllers he had in there. Plus, it's not like you need to shift it. So eliminate the shifter and that whole assembly too (which opens up the area under the floor even more.

While you are at it, might as well just throw on some of those flexible solar panels on the roof. If you are going to go EV, might as well got all out.

[Kudagra]

[airschooled]

Funny enough, doing the conversion anywhere outside of Southern California is going to cost you $5-10k extra in shipping.

Batteries under the floor introduce complexity that is probably not worth the effort on a 100-mile town car. Anyone doing a project like this has to know their skills and set reasonable expectations. If sinking the batteries four more inches matters enough to add months and thousands more to the project, and that’s ok for you, awesome. I am of the mindset that 98% in three months is better than 99% in six.

I really hope OP can get their swap done and bring some more knowledge to the table. For now, we wait on all the iBooster threads that fizzled out..

Robbie
_________________
WTB: 215mm Type 4 flywheel. Cash in hand.

One-on-one tech help for your vintage Volkswagen:
www.airschooled.com

Road trip reports and tech blog:
https://www.patreon.com/airschooled

[Kudagra]

[79 EV VW]

First the weight of batteries. Each 280 Ahr cell weighs 5.7 kg = 12.5lbs and has 890 whr of energy. I will be using 36 cells, for a battery weight of 450 lbs., and total energy of 32 kwhr.The battery box will add another 15 lbs.

My layout will have the batteries on the floor in front of the cargo area, and partially under the new (to be installed) rear bucket seats. This gives lower CG, a usable cargo space, better F-R balance, and still have lots of rear leg room. I did not calculate the total weight or distribution, but I believe it will be less than an engine and gas tank. And I will have a max of 3 passengers.

The title will definitely have to be adddressed before worrying about getting registered as an EV. Starting with an older doner bus with a clear title is a good idea with 2 problems: rust and cost. I only paid $3800 for my donor, and the rust spots are minimal because it was stored in a barn for 15years. I can deal with the DMV for that savings

[79 EV VW]

I really did not tell the whole truth about my EV conversion experience. I did not help my son convert a jeep to EV, he helped me. I did all the conversion work myself, he helped me pull the engine, and that is all. I did write a thread on a jeep forum detailing the Jeep build, which took a year or more. See the jeep thread at https://www.jeepforum.com/threads/cj5-plug-in-ev.4487521/ The last 1/2 of the thread is the part were I got lots of EV experience

The jeep is a successful conversion, and it currently resides in ST Paul MN, where I spend my summers with my grandkids. The jeep is fun to drive but was not suited for rainy winters in CA, with no heat and no doors. That is why I chose to convert a VW bus as my next project: fully enclosed with a heater and defroster. The VW will be my fun CA vehicle

The CJ-5 build was interesting becaus the jeep is so small. I had 3 battery boxes, Including one installed in the gas tank area. Putting batteries under a VW bus would be much easier, as there is more room, and is not confined by frame members.

The comment about gaining 4 inches by putting the batteries under the bus floor is right on. Too much trouble for a small gain and much more difficult to instal. However you do gain more than 4 inches . The CG on my battery boxes is about 5 inch above the floor with a 10 in high box. That means you moves the CG about 14 inch down taking 3inch frame rails and spacing into account. That is a lot for 450 lbs of battery.

[aeromech]

I can’t wait to see pics of your completed project.
_________________
Lead Mechanic: San Diego Air and Space Museum
Licensed Airframe and Powerplant Mechanic
Licensed Pilot (Single engine Land)
Boeing 727,737-200-300-400,757,767
Airbus A319,320,321
DC9/MD80
BAe146
Fokker F28/F100
VW type 1 1962,63,65,69,72
VW Type 2 1971 (3 ea.) 1978, 1969
VW Jetta
VW Passat
Capable of leaping tall buildings in a single bound

[79 EV VW]

On the subject of shipping costs. I did not separate out the shipping cost from the rest of the parts and battery, but I seem to remember about $680 to ship from Canada.

I am using canEV as my supplier. They have been good to work with and provide a couple of deals that are hard to beat. First, by shipping the batteries, motor and electronics as a kit, the avoid the 15%-30% tariff on chinese batteries shipped to the US. Electic power drive trains are exempted. Second canEV has designed and prototyped a modular Battery box system that they premiered at the Everything Electric show in Vancouver September 5-7 this year. The modular system has the BMS and Contactor/relays installed inside the battery box. This is wired at the factory, so all you have to do is cable the battery boxes to the motor controller and battery charger. canEV supples the cables so this is close to a plug-and-ply design.

Since I already built the jeep using the same components, canEV is supplying me the first modular kit and I agreed to do an installation comparison. BTW that is another reason to install battery boxes on the floor, not under the floor. You get some latitude on your battery box size, but you cannot customize it to fit into a confined space.