ICE Breaker - converting a 1967 split to electric drive

[Kevin Sharpe]

I'm using VAG pattern driveshafts in the prototype... my only concern is that the 250HP versions fitted to the Audi TT / Golf R32 may not survive

[Kevin Sharpe]

While we continue our deliberations on the battery box design, my thoughts have turned to the instrumentation

I intend to have a tablet mounted on the overhead ventilation duct which will display detailed system data. However, I also want a 'speedometer' that can be used as the only instrument for everyday driving.

Traditionally the split bus has a single 4.5" (115mm) gauge which could potentially be increased to 5.5" (140mm) without any major changes to the metalwork.

I have been unable to find any off the shelf solutions to-date and I'm therefore investigating the possibility of reverse engineering gauges from the New Beetle, VW Mini, Porsche, and others. Obviously these could be engineered to 'look' traditional while providing instrumentation more suitable for use in an electric vehicle.

That said, I'm also fascinated by the opportunities offered by modern OEM displays such as those fitted to the Fiat 500 which includes both a partial and full LCD variant in a 7" display format

[mandraks]

i like the stuff that jonathan ward builds (youtube). all his cars are from the 50s to the 80s. He works with Dakota Digital and is always able to marry vintage aesthetics with modern technology.
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regards

Uli

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'53 3-Fold Oval, L35 Metallic Blue, looking for a narrow hatch panel

[Kevin Sharpe]

[Kevin Sharpe]

Lots fabrication underway on the main battery box (located between the main chassis rails) which I'll share next week

In the meantime I'm playing with electric parking brakes from the BMW X5/X6

[Kevin Sharpe]

We modified the Tesla cups so that we can test the VAG driveshafts with the 'small' drive unit

[Kevin Sharpe]

First stage of the main battery box fabrication is nearing completion. This steel structure will be welded into place between the main chassis rails providing additional stiffness to the VW chassis and a sealed enclosure for eight Tesla modules

[ivwshane]

Awesome build and I nearly missed it because I mostly post in the bay forum.

Do you have any more info about the company that was building a DIY system using Tesla parts for air cooled vw's?

I am planning to convert my ghia to electric but so many new things are coming out (electric transmissions, better batteries) including being able to use Tesla setups that I'm forced to impatiently wait while the innovation comes to the diyer.
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77 westy 2.0 FI
69 ghia coup 1600dp
70 single cab

[Kevin Sharpe]

[Kevin Sharpe]

Good progress on the panel that will become the 'floor' of the main battery box. This structure will be inverted and the box section welded to the reinforced main chassis members providing a sealed cavity for eight battery modules. Every bolt has a corresponding nut that is welded to the box section and final airtightness will be provided by sealant similar to that used on the Nissan/Tesla batteries

[Kevin Sharpe]

Main battery box lining test fitting

[StefDS]

great work/engineering!

please keep posting progress

[Kevin Sharpe]

[Kevin Sharpe]

We spun up the Tesla drive unit for the first time this week... I'll record some video once we have the driveshafts fitted.

In the meantime here's the 'large' drive unit with the open source controller


Link

[Kevin Sharpe]

Main battery box lining being prepared for spot welding to the floor I beams

[Kevin Sharpe]

Main battery box 'floor' structure ready for welding to the bus chassis rails (note holes for fire exhaust valves at each end of battery box)

[Kevin Sharpe]

Main battery box awaiting seam welding

[Kevin Sharpe]

Rather a lot of seam welding

[Kevin Sharpe]

Nice paint job

[dumptuck]

This is an awesome thread, I hope one day to do the same for my bus!