The "new" older EV

"Wow...this is so much better" - me

After examining possible donor vehicles, I concluded that for my budget and engineering skills, going backwards would move me forward. Old Volkswagens make excellent conversions due to their simplicity, and access to open spaces for battery layout. I really wanted something sporty like the Bradley GT II sports car kit or a Karman Ghia but I needed something that seats 4 and Karman donors are rare and usually in very rough shape.

When I found this Beetle already converted for only $2500.00 I saw it as a chance to get my 4-seater and have my work done for me. It also gives me a chance to examine the engineering in case I decide to repeat the creation in a Karman Ghia later.

As you can tell from the picture, it's kind of anti-climactic. Unless you're a classic Beetle fan of course. These cars have survived for decades because of their sturdy engineering, their simplicity and practicality. Parts are plentiful and CHEAP. Aftermarket parts are available everywhere.

Here are the stats as it was when I bought it:

1. 128 volt system. 16, 8 volt golf-cart batteries (up from the paltry 72 volts of the old Comuta Van)

2. PFC 20 onboard charger from Manzanita Micro technologies. The charger alone is worth $1550.00. It can utilize any input power from 60 volts to 240 volts AC. It can output 12 to 360 volts DC at up to 20 amps. It's small and mounts onboard.

3. A heater! Thank God... It has a 1500w ceramic heater. It only runs when the car is plugged in but it makes for a cozy car in the morning and the heat usually lasts until I arrive at my destination.

4. DC to DC converter. This is an upgrade over using a heavy marine battery to power the 12v stuff like headlights, horn, etc. The converter taps the total battery pack and steps it down to 14 volts. This keeps the headlights bright, the wipers snappy and the horn good and loud. The SEVCON converters were built for underground mining cars so they're easily tough enough to withstand automotive use. It's also small and light and mounts under the back seat. It draws very little amperage and doesn't really affect your total range. It also prevents uneven discharge from tapping the traction pack at mid-point to get your 12 volts because you're tapping the total pack.

5. Advance DC 6.7" motor. This is actually a bit on the small side but I find that the car is fast enough. An 8" motor would have been better.

6. Curtis 1221B motor controller. Same as the Comuta Van. I'm actually 8 volts over it's limit but there's a fix for that. I'll explain later.

7. Instrumentation. 3 analog meters. 1 for 12 v systems, a 400 amp ammeter to show consumption, and a traction voltage gauge that reads up to 300v DC. The ammeter has failed and needs replaced.

The pans are solid and not rusted. I intend to paint everything with POR15 rust preventative just in case.