In Part II, we will perform the actual conversion, removing all of the internal combustion parts and installing
the electrical components.
Update: April 2009 -
Once the welded polypropylene battery boxes arrived at our shop, we began building the metal frames.
These frames are what secure the battery boxes to the vehicle. At this point we removed the internal
combustion engine and related parts, (i.e. gas tank, smog components, etc...) After the frames were
constructed they were custom mounted to the vehicle. There are a total of three boxes. Two batteries
are to be located under the front bonnet where the gas tank was housed. Six batteries occupy the area
where the rear seat was located, with four additional batteries in the area behind the rear seat.
We are currently waiting the arrival of the electric motor.
Update: May 2009 -
As the month began, we were still waiting on several main components; motor, controller, DC to DC
converter, charger, state-of-charge gauge, and amp meter shunt. While waiting for parts, we cleaned
and painted the battery box frames.
The motor was received just before Memorial Day weekend, the controller, DC to DC converter, and
charger arrived at the end of the month.
Update: June 2009 -
June looks to be a busy and exciting month. With almost all the components in stock, we have shifted to
high gear to get back on schedule. The front battery box has been installed, along with the battery
charger and related wiring. The front battery box vent system is also in place. The vent system comes
on automatically when the vehicle is being charged. It can also be switched on manually while the vehicle
is being driven to help cool the battery packs. The system is designed to allow air movement while the
vehicle is in motion, via a scooped intake set-up. We also designed and built a housing/mount for the
circuit breaker, which is located in easy reach of both driver and passenger.
With the motor in our possession, we installed the adapter plate, lightened flywheel, and heavy-duty
clutch.
June turned out to be a busy month alright, so busy we did not have a chance to make much progress on
the conversion.
Update: July 2009 -
Finally moving forward. Cleaned, inspected, repacked and replaced boots on constant velocity joints.
Installed motor assembly in vehicle, and lay out for the heat-sink. The heat-sink is a 12" x 24" x 1/4" piece
of aluminum to which we mounted the controller, main contactor, shunt, pot box, etc. It is spaced away
from the firewall to allow air to circulate. We ran our wiring looms from front to rear and connected the
components on the heat-sink. The middle and rear battery boxes were installed and batteries purchased.
The rear and middle battery box venting system was installed and tested. The battery box lids and
battery hold downs were made and the batteries installed. The State-of-Charge gauge arrived and was
also installed. The 12 volt system was tested and everything looks good to go. We're close to having the
conversion complete.
Update: August 2009 -
Finished making all of the battery interconnects and installed the PakTrakr. Battery box lids were bolted
in place, and we were ready for testing. The circuit breaker was switched on, the throttle pushed, and the
motor came to life. The first day we drove a little over 18 miles and took her up to 60 MPH. Currently we
have gone 98 miles and have achieved 70 MPH. We have tested the Bug on the freeway, cruising 65
MPH for 10 miles in hilly terrain. The Bug has pulled some steep grades and has good acceleration. All
systems have been working perfectly. The batteries recharge in 5 to 6 hours and our range looks to be
approximately 40 miles at 45 - 50 MPH. We are going to weigh the Bug and continue road testing until
late September, when we will tear everything apart and start the restoration portion of the project.
Update: August 14, 2009 -
Over 300 miles since conversion and everything working as it should. Weighed Bug and it tipped the
scales at 2580 lbs. The Bug will be participating in the East Bay Electric Auto Association's EV
Display/Rally on August 22, 2009 at Chabot College in Hayward California. For more information about
the event, visit their website at www.ebeaa.org.
Update: August 16, 2009
Continuing to drive and test the Bug. All systems have been working perfectly. Decided to get some
performance stats. 0 to 60 time was 16 seconds, about the same as it was with the gasoline engine. Top
speed 85+ MPH. Range in mixed driving 30+ miles.
Update: August 22, 2009
Attended the East Bay EV Rally in Hayward, California and received positive reviews on the Bug's
conversion.
As a matter of fact, the Bug was very well received and we were encouraged to attend the 37th Annual EV
Rally in Palo Alto, California. After the Hayward Rally the Bug made a brief stop in Fresno, California,
again receiving positive reviews.
Update: August 29, 2009
Made the trip to Palo Alto for the 37th Annual EV Rally held there. The Bug again was one of the focal
points of the show. The classic Bug lines and the well engineered conversion made the Bug one of the
crowds favorites.
Update: September 4, 2009
The Bug has been invited to attend the Concours d'Elegance at Chico State University on Sunday,
September 13, 2009. The Bug will also be in Chico, California on Saturday, September 12, 2009 as the
featured topic of the local EAA Club meeting.
The Bug has logged over 700 miles since being converted and is operating flawlessly. Later this month
we will begin the third and final part of this project with the start of the body work. When all is said and
done, the Bug will have new paint, glass, gaskets, tires, wheels and custom interior. We hope to have this
all completed in time for the Kool April Nites car show in Redding, California in April 2010.
Update: November 2009
The Bug has been driven over 1500 miles and is a blast to drive. It has been so much fun to drive, that
our original plan of getting it painted at the end of September didn't happen. But we must move forward,
so the first part of December should see the Bug in the paint shop. But first we have to strip it down. All
of the conversion components will be removed, as well as the trim, glass, gaskets, etc. Nothing to it, but
work. So, for continued updates, check Part III as we follow the progress of the last leg of our VW Beetle
conversion.
See ya in Part III....
the electrical components.
Update: April 2009 -
Once the welded polypropylene battery boxes arrived at our shop, we began building the metal frames.
These frames are what secure the battery boxes to the vehicle. At this point we removed the internal
combustion engine and related parts, (i.e. gas tank, smog components, etc...) After the frames were
constructed they were custom mounted to the vehicle. There are a total of three boxes. Two batteries
are to be located under the front bonnet where the gas tank was housed. Six batteries occupy the area
where the rear seat was located, with four additional batteries in the area behind the rear seat.
We are currently waiting the arrival of the electric motor.
Update: May 2009 -
As the month began, we were still waiting on several main components; motor, controller, DC to DC
converter, charger, state-of-charge gauge, and amp meter shunt. While waiting for parts, we cleaned
and painted the battery box frames.
The motor was received just before Memorial Day weekend, the controller, DC to DC converter, and
charger arrived at the end of the month.
Update: June 2009 -
June looks to be a busy and exciting month. With almost all the components in stock, we have shifted to
high gear to get back on schedule. The front battery box has been installed, along with the battery
charger and related wiring. The front battery box vent system is also in place. The vent system comes
on automatically when the vehicle is being charged. It can also be switched on manually while the vehicle
is being driven to help cool the battery packs. The system is designed to allow air movement while the
vehicle is in motion, via a scooped intake set-up. We also designed and built a housing/mount for the
circuit breaker, which is located in easy reach of both driver and passenger.
With the motor in our possession, we installed the adapter plate, lightened flywheel, and heavy-duty
clutch.
June turned out to be a busy month alright, so busy we did not have a chance to make much progress on
the conversion.
Update: July 2009 -
Finally moving forward. Cleaned, inspected, repacked and replaced boots on constant velocity joints.
Installed motor assembly in vehicle, and lay out for the heat-sink. The heat-sink is a 12" x 24" x 1/4" piece
of aluminum to which we mounted the controller, main contactor, shunt, pot box, etc. It is spaced away
from the firewall to allow air to circulate. We ran our wiring looms from front to rear and connected the
components on the heat-sink. The middle and rear battery boxes were installed and batteries purchased.
The rear and middle battery box venting system was installed and tested. The battery box lids and
battery hold downs were made and the batteries installed. The State-of-Charge gauge arrived and was
also installed. The 12 volt system was tested and everything looks good to go. We're close to having the
conversion complete.
Update: August 2009 -
Finished making all of the battery interconnects and installed the PakTrakr. Battery box lids were bolted
in place, and we were ready for testing. The circuit breaker was switched on, the throttle pushed, and the
motor came to life. The first day we drove a little over 18 miles and took her up to 60 MPH. Currently we
have gone 98 miles and have achieved 70 MPH. We have tested the Bug on the freeway, cruising 65
MPH for 10 miles in hilly terrain. The Bug has pulled some steep grades and has good acceleration. All
systems have been working perfectly. The batteries recharge in 5 to 6 hours and our range looks to be
approximately 40 miles at 45 - 50 MPH. We are going to weigh the Bug and continue road testing until
late September, when we will tear everything apart and start the restoration portion of the project.
Update: August 14, 2009 -
Over 300 miles since conversion and everything working as it should. Weighed Bug and it tipped the
scales at 2580 lbs. The Bug will be participating in the East Bay Electric Auto Association's EV
Display/Rally on August 22, 2009 at Chabot College in Hayward California. For more information about
the event, visit their website at www.ebeaa.org.
Update: August 16, 2009
Continuing to drive and test the Bug. All systems have been working perfectly. Decided to get some
performance stats. 0 to 60 time was 16 seconds, about the same as it was with the gasoline engine. Top
speed 85+ MPH. Range in mixed driving 30+ miles.
Update: August 22, 2009
Attended the East Bay EV Rally in Hayward, California and received positive reviews on the Bug's
conversion.
As a matter of fact, the Bug was very well received and we were encouraged to attend the 37th Annual EV
Rally in Palo Alto, California. After the Hayward Rally the Bug made a brief stop in Fresno, California,
again receiving positive reviews.
Update: August 29, 2009
Made the trip to Palo Alto for the 37th Annual EV Rally held there. The Bug again was one of the focal
points of the show. The classic Bug lines and the well engineered conversion made the Bug one of the
crowds favorites.
Update: September 4, 2009
The Bug has been invited to attend the Concours d'Elegance at Chico State University on Sunday,
September 13, 2009. The Bug will also be in Chico, California on Saturday, September 12, 2009 as the
featured topic of the local EAA Club meeting.
The Bug has logged over 700 miles since being converted and is operating flawlessly. Later this month
we will begin the third and final part of this project with the start of the body work. When all is said and
done, the Bug will have new paint, glass, gaskets, tires, wheels and custom interior. We hope to have this
all completed in time for the Kool April Nites car show in Redding, California in April 2010.
Update: November 2009
The Bug has been driven over 1500 miles and is a blast to drive. It has been so much fun to drive, that
our original plan of getting it painted at the end of September didn't happen. But we must move forward,
so the first part of December should see the Bug in the paint shop. But first we have to strip it down. All
of the conversion components will be removed, as well as the trim, glass, gaskets, etc. Nothing to it, but
work. So, for continued updates, check Part III as we follow the progress of the last leg of our VW Beetle
conversion.
See ya in Part III....
| Part II: The Conversion |
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