ICE Breaker - converting a 1967 split to electric drive

[Kevin Sharpe]

[Kevin Sharpe]

Some very good progress with the open source inverter for the Tesla motor... rapidly getting to the point where we have full control


Link

[Kevin Sharpe]

We hope to 3D scan the 'small' Tesla rear motor in the next couple of weeks... we *think* we have a solution that will allow any of the early VW vehicles to use the Tesla drivetrain easily

While we wait here are a few photo's that give an indication of the overall size of the drivetrain that we are using.

[Kevin Sharpe]

PCB layout for the 'small' Tesla motor is going well

More on the open source design can be found here;

https://www.patreon.com/posts/tight-fit-14515911

[Kevin Sharpe]

I'm receiving several messages a day requesting help buying Tesla parts. While I'm thrilled to see this market taking off I thought it would be more efficient if the DIY community created a list of resellers/breakers and (hopefully) provided a personal recommendation to ensure this is useful.

I've made a start here

[Kevin Sharpe]

The bus is currently at the workshop where the prototype motor mounts are being fabricated. I hope to have some progress to report in a couple of weeks time.

In the meantime we've just received another 'small' Tesla drive unit which is destined for a 1976 Beetle Karmann Cabriolet conversion that a friend is undertaking

[Kevin Sharpe]

We're making progress on the 3D scans and have today found a company that can 3D print full size copies of the drive units, battery modules, and chargers. The plan is to create low cost space models of the Tesla parts that anyone can use during the conversion planning stage.

At the other end of the scale, we've been fabricating physical models to help visualise the mechanical constraints (sometimes easier when you don't have 3D models of the vehicle)

[SplitBusVanatic]

This is a great thread and along with Jehu is a valuable addition to the 'Split Bus' section of the TheSamba.
Currently, are the tesla units expensive to buy off the shelf new or are you sourcing yours second hand ?

[Kevin Sharpe]

It looks like we'll have a lot of space left after our ~250HP motor upgrade

[Kevin Sharpe]

[Kevin Sharpe]

We have the prototype engine mounts fabricated and the 'small' Tesla rear motor installed ready for inverter testing

The only cut on the bus was the centre of the lowest cross member which we think we can save in a future version of the motor mount design. Everything bolts onto the bus including the Red 9 IRS system that I'm using.

Next step is to verify this design approach works on a beetle chassis. Then we'll give the prototype to a couple of engineering companies who will turn it into products that we can all buy

[SplitBusVanatic]

Great progress. Well done.

[Kevin Sharpe]

[Kevin Sharpe]

We’ve been busy working on the Red 9 suspension system and hope to have the wheels back on the bus next week ready to test Damien’s open source inverter controller

In parallel with these efforts we’re showing the prototype motor mounts to a couple of companies that want to make them commercially.

And in the quiet moments we’re kitting parts for four Tesla based conversions

[Kevin Sharpe]

Here's the version 2 Tesla motor mount prototype which fits on the standard VW Bus/Beetle engine frame horns without modification.

This version also accommodates the Red 9 IRS when fitted to the Split Screen Bus

[pyrOman]

Looks really clean! WOW!
_________________
Some people are so busy being clever they don't have time enough to be wise.

[vwwestyman]

Interesting...

I drove an old-school (well, mid 90s) electric conversion in a '73 Beetle in May. Was the standard mount the motor to the gearbox conversion, but was still super neat to drive.

Maybe when a few more Teslas have been crashed, I'll want to mount one in my Thing! It's got the same type of frame horns as a beetle, so this should work, right? Would be a cool motor conversion that wouldn't require locating a radiator.
_________________
Dave Cook

President, Wild Westerner Club

1978 Champagne Edition Westy, repowered to '97 Jetta TDI
1973 Wild Westerner
My Thing

[Kevin Sharpe]

[vwwestyman]

Shoot on the radiator requirement! I suppose it makes sense that even an electric motor making that power would indeed need cooling.

It'll be super interesting to see how the range in a Bus or Beetle (or Thing!) compares to the original car.
_________________
Dave Cook

President, Wild Westerner Club

1978 Champagne Edition Westy, repowered to '97 Jetta TDI
1973 Wild Westerner
My Thing

[mandraks]