In the beginning...well maybe not that long ago, there was an economy car that out sold every other
vehicle on the planet, the Volkswagen Beetle. Originally designed in the 1930's by Ferdinand Porsche, it
was sold in the US until the late 1970's. Once so popular that you could not find a parking lot without
several Beetles in view. Today they are seldom seen, but we are bringing one back from near extinction.
Found in Chico, California, dirty, rusting, and neglected, we managed to drive it the 83 miles to our shop
in Shasta Lake. We are currently cleaning and repairing the Beetle to be road worthy, and to handle the
weight of the batteries, approximately 1,200 pounds.
Electric vehicles first appeared around 1912, but were slow, heavy and did not have much range. The
limiting factor has always been the batteries, as it is today. However, new advances in battery technology
is about to change all that, with major auto and battery manufacturers putting an unprecedented amount
of resources into the next generation of hi-tech batteries. But we're not waiting for new technology, we're
going to use the old standard, lead-acid batteries. While heavier and requiring longer recharge times,
lead-acid batteries are more affordable than, say lithium-ion.
Currently, in addition to the R & D of the conversion to electric, we will be testing the Beetle under load to
address braking and handling issues. The Beetle is not in stock condition, over the years it has been
lowered and has had fiberglass fenders added, which are 2-1/2 inches wider than stock. The interior is
stripped and it is a noisy and bumpy ride.
When finished, the Beetle will have a new interior, paint, tires and wheels, and require NO GAS. Our goal
is to use the Beetle as a sales and a marketing tool.
Update: November 2008 -
We have cleaned and repaired the Bug to be road worthy, added air shocks on the rear, and have been
road testing with the stock internal combustion engine (ICE). The current weight of the Bug without a rear
seat and a stripped interior is 1660 pounds. The 0 to 60 time is approximately 16 seconds. After
completing tests (acceleration, cornering, rough roads, grades, etc.) with the Bug unloaded, we are now
testing different loads and different load configurations.
Our first choice for a battery was the Trojan J150, an excellent battery, but unfortunately too heavy for the
Bug. The weight of batteries and boxes was approximately 1200 pounds, making the total weight 2860
pounds, well over the 2710 GVW of the Bug.
Our second choice for a battery is lighter, 60 lbs. versus the 84 lbs. of the J150. We are currently testing
a total load of 780 pounds, with 660 lbs. in the rear and 120 lbs. up front. So far, this is the set-up that
works the best.
The Bug will be powered by a 144 volt system, twelve 12 volt batteries wired in series. We wanted to
keep all the batteries as close together as possible, but due to weight and handling concerns, it looks like
we'll have to split the battery pack with two batteries up front and ten in the rear. The Bug is being driven
and tested daily, see updates.
Update: December 2008 -
Our most recent load test was with a total weight of 840 pounds, 660 pounds in the rear, and 180 pounds
up front. This better represents having two traction batteries and the auxiliary battery up front and ten
traction batteries in the rear.
Based on the result of the above testing, we've decided to increase the front suspension by adding
coil-over shocks and front disc brakes. After making these changes, we will again do a load test to make
sure we have satisfactory results. If necessary we'll add disc brakes in the rear also.
Update: January 2009 -
The results are in, adding the coil-over shocks did the trick. With the coil-over shocks on the front and air
shocks on the back we were able to achieve the same ride height loaded as we had originally unloaded.
The front disc brakes also made quite a difference, however, due to the lack of engine braking with the
electric setup, and for an additional margin of safety, we have decided to add rear disc brakes also.
In addition to the front disc brakes and coil-over shocks, we also replaced the ball joints and tie rod ends,
and had the front end aligned. We will also be adding a heavy duty anti-sway bar on the front.
Update: February 2009 -
February was spent in research, mainly regarding batteries. The batteries selection is critical, and a lot of
time and research went into finding and deciding which battery to use. Our final decision is to use a
Trojan Model #30XHS, which weigh 66 lbs. each. That makes our total battery pack weight 792 pounds!
That does not include the weight of the battery boxes and mounts. Different vehicles accommodate
different battery possibilities. Our goal is to best balance performance and range of this vehicle.
Update: March 2009 -
After months of research, it feels like we are starting to make some headway. We installed rear disc
brakes and a heavy-duty front anti-sway bar. The polypropylene battery containment boxes are being
built, and most of the electric conversions parts are on order. Expected delivery time is late April to early
May. We should have the battery boxes ready for mounting in early April. Check the Photo Gallery for
updated photos.
Continued in Part II...
vehicle on the planet, the Volkswagen Beetle. Originally designed in the 1930's by Ferdinand Porsche, it
was sold in the US until the late 1970's. Once so popular that you could not find a parking lot without
several Beetles in view. Today they are seldom seen, but we are bringing one back from near extinction.
Found in Chico, California, dirty, rusting, and neglected, we managed to drive it the 83 miles to our shop
in Shasta Lake. We are currently cleaning and repairing the Beetle to be road worthy, and to handle the
weight of the batteries, approximately 1,200 pounds.
Electric vehicles first appeared around 1912, but were slow, heavy and did not have much range. The
limiting factor has always been the batteries, as it is today. However, new advances in battery technology
is about to change all that, with major auto and battery manufacturers putting an unprecedented amount
of resources into the next generation of hi-tech batteries. But we're not waiting for new technology, we're
going to use the old standard, lead-acid batteries. While heavier and requiring longer recharge times,
lead-acid batteries are more affordable than, say lithium-ion.
Currently, in addition to the R & D of the conversion to electric, we will be testing the Beetle under load to
address braking and handling issues. The Beetle is not in stock condition, over the years it has been
lowered and has had fiberglass fenders added, which are 2-1/2 inches wider than stock. The interior is
stripped and it is a noisy and bumpy ride.
When finished, the Beetle will have a new interior, paint, tires and wheels, and require NO GAS. Our goal
is to use the Beetle as a sales and a marketing tool.
Update: November 2008 -
We have cleaned and repaired the Bug to be road worthy, added air shocks on the rear, and have been
road testing with the stock internal combustion engine (ICE). The current weight of the Bug without a rear
seat and a stripped interior is 1660 pounds. The 0 to 60 time is approximately 16 seconds. After
completing tests (acceleration, cornering, rough roads, grades, etc.) with the Bug unloaded, we are now
testing different loads and different load configurations.
Our first choice for a battery was the Trojan J150, an excellent battery, but unfortunately too heavy for the
Bug. The weight of batteries and boxes was approximately 1200 pounds, making the total weight 2860
pounds, well over the 2710 GVW of the Bug.
Our second choice for a battery is lighter, 60 lbs. versus the 84 lbs. of the J150. We are currently testing
a total load of 780 pounds, with 660 lbs. in the rear and 120 lbs. up front. So far, this is the set-up that
works the best.
The Bug will be powered by a 144 volt system, twelve 12 volt batteries wired in series. We wanted to
keep all the batteries as close together as possible, but due to weight and handling concerns, it looks like
we'll have to split the battery pack with two batteries up front and ten in the rear. The Bug is being driven
and tested daily, see updates.
Update: December 2008 -
Our most recent load test was with a total weight of 840 pounds, 660 pounds in the rear, and 180 pounds
up front. This better represents having two traction batteries and the auxiliary battery up front and ten
traction batteries in the rear.
Based on the result of the above testing, we've decided to increase the front suspension by adding
coil-over shocks and front disc brakes. After making these changes, we will again do a load test to make
sure we have satisfactory results. If necessary we'll add disc brakes in the rear also.
Update: January 2009 -
The results are in, adding the coil-over shocks did the trick. With the coil-over shocks on the front and air
shocks on the back we were able to achieve the same ride height loaded as we had originally unloaded.
The front disc brakes also made quite a difference, however, due to the lack of engine braking with the
electric setup, and for an additional margin of safety, we have decided to add rear disc brakes also.
In addition to the front disc brakes and coil-over shocks, we also replaced the ball joints and tie rod ends,
and had the front end aligned. We will also be adding a heavy duty anti-sway bar on the front.
Update: February 2009 -
February was spent in research, mainly regarding batteries. The batteries selection is critical, and a lot of
time and research went into finding and deciding which battery to use. Our final decision is to use a
Trojan Model #30XHS, which weigh 66 lbs. each. That makes our total battery pack weight 792 pounds!
That does not include the weight of the battery boxes and mounts. Different vehicles accommodate
different battery possibilities. Our goal is to best balance performance and range of this vehicle.
Update: March 2009 -
After months of research, it feels like we are starting to make some headway. We installed rear disc
brakes and a heavy-duty front anti-sway bar. The polypropylene battery containment boxes are being
built, and most of the electric conversions parts are on order. Expected delivery time is late April to early
May. We should have the battery boxes ready for mounting in early April. Check the Photo Gallery for
updated photos.
Continued in Part II...
| Part I: The Development |
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van Wyhe's Custom Engraving and the sole property of van
Wyhe's Custom Engraving, and may not be used for any
purpose or by anyone other than the owners.
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