Wire harnessMotor Motor MountCompleted battery wiring.Control board and chargersBattery boxController board
OwnerPaul B.
LocationIrvine, California US map
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Vehicle1977 Volkswagen Bus
MotorAdvanced DC FB1-4001A Series Wound DC
EV America conversion parts. Adapter was trimmed down to flow with bellhousing.
DrivetrainStock transaxle rebuilt with new bearings and seals. Clutchless
ControllerCurtis 1231C
96-144 V 500 Amp limit
Batteries12 Trojan T-1275, 12.00 Volt, Lead-Acid, Flooded
System Voltage144 Volts
ChargerQuickcharge Op-144-20 230VAC and OP144-8 115VAC
Two onboard chargers. One for home and the other for when only 110 is available.
HeaterNone - Planning a hairdryer conversion in the near future.
DC/DC ConverterAstrodyne DC-DC SB50
InstrumentationWestberg Voltmeter and Ammeter
Top Speed59 MPH (94 KPH)
I have been up to about 59 mph (downhill). Seems to move along quite well.
AccelerationPretty peppy but I never drove the ICE version so I can't compare. I am satisfied so far.
Range22 Miles (35 Kilometers)
I have only travelled 22 miles before charging. I am trying to slowly break in the batteries.
EV Miles
Start:56,057 Miles (90,195 Kilometers)
Current:56,202 Miles (90,429 Kilometers)
Total:145 Miles (233 Kilometers)
 
    As of 1/5/2009
Seating Capacity5 adults
TiresStandard
Conversion TimeStarted in June 2008 with restoration.

A month and a half of weekends and weeknights. I estimate about 120-130 hours of time spent planning and completing the conversion.
Conversion CostEstimates currently at 12K + for conversion plus vehicle restoration, I am a little afraid to look at the total cost including all the little things that add up near the end.
11-9-08 - I have the engine and tranny mounted and will begin the install of the controller and on-board chargers.

11-10-08 - Built mount for both onboard chargers. They will be mounted in the location of the old gas tank. Built a pair of 2 guage crimpers, these should help make the welding cable look professional and strong.

11-12-08 - Worked on the motor mount to cradle the motor. Looked for possible non-conductive material for controller and contactor board - polycarbonate and high end fiber/composite board (a little costly compared to wood).

11-16-08 - Finished motor mount and installed it. I made the mount from a piece of 2 inch flat stock, 3/16ths thick. I bent the material around a steel ten pound weight. I started work on the mock-up controller board made from plywood. Began construction on 30X40X12 battery box.

11-17-08 - Installed plywood controller board above the motor. It hinges up to allow access to motor power cables. Will start installing all the components and wiring the controller, contacts, relays and DC/DC converter.

11-28-08 - Almosted completed the mock-up controller board. Most of the wiring on the board is done and placement of components have been identified. I have ordered a piece of G10 board for the final controller board.

11-30-08 - Started on the battery box 31x41x12. It will house all twelve Trojan batteries and will be mounted behind the front seats. The box is plywood re-enforced with external aluminum.

12-3-08 - Wired up the relay and fuse box to power the controller board. Still need to run wires to dash for voltmeter and ammeter.

12-4-08 - Mounted vacuum brake pump and switch.

12-12-08 - Completed fiber board for controller and contactors. Batteries are being wired and final wiring to gauges being run.

12-26-08 - Finished up the necessary wiring to get the bus driveable. I towed it down to the DMV and got it smog exempt and listed as an electric vehicle. That was the easiest part of the enitire conversion. Road test to come once fully charged. Road test was a little slow, but I went back and readjusted the throttle cable and pot box and got much better performance.

12-27-08 - Been driving and charging over the past two days. I have about fifteen smiling miles so far. Shifting is not a problem without the clutch. You just take a little time between gears and it slips right in. I have been running second gear up to about 35 and then shifting into third.

12-28-08 - Have taken the bus an several local store trips. I went into fourth gear and got up to 52 mph with no problem.

12-31-08 - Tried my first hill. The hill pulled lots of amps and I felt a significant decrease in performance after the climb. I tried to keep the amps as low as possible and still make it up the hill. I will try to always adjust my route around all hills.

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