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61 Double Cab EV Conversion Build thread
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kiwipip
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PostPosted: Sun Nov 06, 2022 9:41 pm    Post subject: 61 Double Cab EV Conversion Build thread Reply with quote

What seems like eternity, I can finally start the reassembly of the DC. I purchased the DC in 2018 after after it had been sitting for 8 years with the majority of body work completed what was a very solid vehicle to start with.
Well 4 years later (COVID didn't help), its finally back home and the assembly and all the parts I have accumulated over the years can start tone installed.


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The DC was a solid vehicle to start with


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Back to bare metal and countless hours of prep to get it straight


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Final paint ready for assembly


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First thing get the doors back on

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The underside was just as detailed as the top side

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a mix between smooth and textured finishes


Last edited by kiwipip on Sat Nov 19, 2022 9:14 pm; edited 1 time in total
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kiwipip
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PostPosted: Sun Nov 06, 2022 9:45 pm    Post subject: Re: 61 Double Cab Build Thread Reply with quote

Cleaned to Cargo Door Latch and installed it
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Dynamite to the doors
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zimblewinder
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PostPosted: Mon Nov 07, 2022 1:55 am    Post subject: Re: 61 Double Cab Build Thread Reply with quote

great colour, looks a lot like Rob Kings DC here in Oz back in the day.
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Huetti_1989
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PostPosted: Mon Nov 07, 2022 3:50 am    Post subject: Re: 61 Double Cab Build Thread Reply with quote

Cool Colour!
and Clean Work of course!

-Christian
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Braukuche
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PostPosted: Mon Nov 07, 2022 7:42 am    Post subject: Re: 61 Double Cab Build Thread Reply with quote

Wow, starting with a truck that straight and dry is like hitting the lottery.
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kiwipip
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PostPosted: Mon Nov 07, 2022 8:38 pm    Post subject: Re: 61 Double Cab Build Thread Reply with quote

Managed to get both front doors lined with Dynamat, locks and strikers cleaned buffed and installed and all aligned. Just waiting for the chrome platers to finish so i can install the glass.

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kiwipip
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PostPosted: Wed Nov 09, 2022 10:19 pm    Post subject: Re: 61 Double Cab Build Thread Reply with quote

Sorry guys Im posting lots of pics on a daily basis, as Im using the forum to document my rebuild like a Diary.

Today I managed to finish the Dynamat Liner including the roof
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Installed the front Bullet Blinkers

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Installed the EV Charge Flap

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kiwipip
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PostPosted: Sat Nov 12, 2022 9:45 pm    Post subject: Re: 61 Double Cab Build Thread Reply with quote

Started on some of the wiring, Attached the bullet indicators and the Head light Loom.

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Made some mock ups of the Tesla Battery Packs that will sit under the rear bench seat

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BarryL Premium Member
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PostPosted: Sun Nov 13, 2022 6:51 pm    Post subject: Re: 61 Double Cab Build Thread Reply with quote

Did you post somewhere you were going electric with this?
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kiwipip
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PostPosted: Sun Nov 13, 2022 10:49 pm    Post subject: Re: 61 Double Cab Build Thread Reply with quote

BarryL wrote:
Did you post somewhere you were going electric with this?


No up till about 4 months ago I was going down the conventional route even built the motor which is now sitting in my Man Cave. Im a bit reluctant to mention the EV Conversion as there are many haters. The conversion Im doing uses all the standard components with no body modifications, all the electrics modules and battery pack sit in a battery bot under the rear seat so no one will be the wiser.


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Mikee
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PostPosted: Sun Nov 13, 2022 11:27 pm    Post subject: Re: 61 Double Cab Build Thread Reply with quote

That motor would look good in my bus!!



kiwipip wrote:
BarryL wrote:
Did you post somewhere you were going electric with this?


No up till about 4 months ago I was going down the conventional route even built the motor which is now sitting in my Man Cave. Im a bit reluctant to mention the EV Conversion as there are many haters. The conversion Im doing uses all the standard components with no body modifications, all the electrics modules and battery pack sit in a battery bot under the rear seat so no one will be the wiser.


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Glenn Premium Member
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PostPosted: Mon Nov 14, 2022 6:13 am    Post subject: Re: 61 Double Cab Build Thread Reply with quote

You should dump that Kultek POS distributor and get a real 010.
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Braukuche
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PostPosted: Mon Nov 14, 2022 8:15 am    Post subject: Re: 61 Double Cab Build Thread Reply with quote

What sort of range are you looking at with the EV conversion?
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Retirement is here!
1956 Ghia
1959 SO-23 Westfalia
1960 double cab
1960 Baja Bug
1963 stretched double cab
1962 Golde sunroof Ghia
1963 356 B coupe
1963 Notchback
1967 21 window less rusty now
1973 Ghia convertible
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kiwipip
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PostPosted: Mon Nov 14, 2022 11:18 am    Post subject: Re: 61 Double Cab Build Thread Reply with quote

Braukuche wrote:
What sort of range are you looking at with the EV conversion?


I’m expecting somewhere around the 100~120 mile range, if I wanted to double the range I double the battery storage as there is ample room under the rear seat for double the battery capacity but adds another roughly $9K USD to the kit.

Range wasn’t an issue for the build as it will be used on the odd weekend to go the the local shops etc. I have a few great cars and if I wanted to go in an extended trip the DC would be my last choice in a long distant jaunt for safety speed or comfort
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Braukuche
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PostPosted: Mon Nov 14, 2022 2:12 pm    Post subject: Re: 61 Double Cab Build Thread Reply with quote

kiwipip wrote:
Braukuche wrote:
What sort of range are you looking at with the EV conversion?


I’m expecting somewhere around the 100~120 mile range, if I wanted to double the range I double the battery storage as there is ample room under the rear seat for double the battery capacity but adds another roughly $9K USD to the kit.

Range wasn’t an issue for the build as it will be used on the odd weekend to go the the local shops etc. I have a few great cars and if I wanted to go in an extended trip the DC would be my last choice in a long distant jaunt for safety speed or comfort


Thanks for the info.
I was curious because I think a double cab makes a perfect candidate for conversion without messing up the original metal of the vehicle or having to take up usable space for batteries.
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Go Reds! Smash state!

Retirement is here!
1956 Ghia
1959 SO-23 Westfalia
1960 double cab
1960 Baja Bug
1963 stretched double cab
1962 Golde sunroof Ghia
1963 356 B coupe
1963 Notchback
1967 21 window less rusty now
1973 Ghia convertible
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Dangermouse
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PostPosted: Mon Nov 14, 2022 8:07 pm    Post subject: Re: 61 Double Cab Build Thread Reply with quote

That is such a sweet truck; whereabouts are you? So looking forward to seeing this out there. Inspirational stuff for me still at the crusty end of my single cab project Laughing
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kiwipip
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PostPosted: Mon Nov 14, 2022 10:30 pm    Post subject: Re: 61 Double Cab Build Thread Reply with quote

Dangermouse wrote:
That is such a sweet truck; whereabouts are you? So looking forward to seeing this out there. Inspirational stuff for me still at the crusty end of my single cab project Laughing


Im in Auckland the DC is at my man cave in St Johns, don't know where you are based but you more than welcome send me a PM and I can flick you my number and you can have a look cheers
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Dangermouse
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PostPosted: Tue Nov 15, 2022 7:15 pm    Post subject: Re: 61 Double Cab Build Thread Reply with quote

Ah, I'm down the other end, in Dunedin. Otherwise I'd be straight around for a look... But will be following this thread with great interest. That underside; so clean you could eat your dinner off it Laughing
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kiwipip
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PostPosted: Wed Nov 16, 2022 10:39 pm    Post subject: Re: 61 Double Cab Build Thread Reply with quote

Was up under the Dash today have done the bulk of the wiring, Just waiting for Turn Signal switch to come back from the painters (Red same as the Dash) then that will be completed. Installed the Headlights another "What I thought would be a 5 minute job" once again bite me on the Ass but they are in.

Thank God for this forum and Google as I never tore down the DC the little things get me baffled like (How the fuse box stays in the holder mmm a little spring clip,, How the rear lid stay operates how does the spring attach and a little thing like where do I mount the Earth strap as I thought that hole was for the engine lid stay.

Hopefully next week I can install the new Discs for front and rear, install brake lines etc

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Headlights installed

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Wiring all but completed just waiting for the refurbished speedo to finish the last of the remain wires test it the secure and tidy it all up

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So this is where the Earth strap mounts. (yes I marked it ground it to bare metal and used some Dielectric grease to ensure a good contact
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kiwipip
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PostPosted: Sat Nov 19, 2022 9:39 pm    Post subject: Re: 61 Double Cab EV Conversion Build thread Reply with quote

I have edited the title to EV Build, I know there will be plenty of haters and purists that will persecute me for doing this, but I have made sure this is a bolt in kit. There are body modifications all the battery packs controllers etc fit under the rear seat, uses the existing throttle pedal etc.

If at a later date someone wants to convert it back it just a matter of unbolting the EV Motor of the gear box and remove the Battery box from under the rear seat.


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Kit arrived from Netherlands

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Motor and Tesla Battery Modules

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The Old and the New

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Charge port a perfect fit in the existing gas filler location
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