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25 February 2018

It’s Electric!

A 1974 Volkswagen Karmann Ghia Electric conversion that is beautiful, handles like a dream, fast and economical. Jarrod Botttinelli is the owner and provides a great summary and run down on the specifics. “Using a Warp 11 DC motor for a car this size seemed like overkill, but why bother doing a conversion if its not going to scream? It has unbelievable torque at low rpm. It burns rubber in 2nd and even 3rd gear. But I was surprised by how much more pronounced the effect from back EMF is, which begins at a lower rpm and is stronger. However, driving all the time in 4th gear keeps rpms low, solving that problem (motor heating hasn’t been an issue either, because this giant motor doesn’t even seem to notice this little car! It runs much cooler than the Warp 9 in my bug). The Ghia is much more stable and quiet at 90 mph than the bug”. The motor is a Netgain Warp 11 Series Wound DC. Drivetrain is a stock transaxle, will upgrade to KCR performance transmission with 3.44 R&P, welded 3rd and 4th gears, super differential. Kennedy stage III clutch, lightened EV specific aluminum flywheel from EV West Controller
Zeva MC 1000 (1000 amp)Very impressed with this controller. When combined with the EVMS, programming and
monitoring many controller parameters is very easy. Linked with CAN Bus interface. Much thanks to Ian Hooper of ZEVA for extremely good customer support.Batteries are 45 Voltronix 180 Ah, 3.20 Volt, Lithium Iron Phosphate24 behind seats, 21 under hood. System Voltage 144 Volts, Charger Elcon PFC 1500. Heater is a homemade from heating element of a 1500W space heater engaged by 400 amp contactor and 12 volt 270 cfm marine blower. Works very well. The DC/DC Converter is a Meanwell SD-1000H-12, Instrumentation is an EVMS monitor, Speed Hut Speedo and Tach, No BMS, individual voltage meters on each cell, temperature gauges for both battery packs and motor.
Top Speed is 95 MPH (152 KPH) and will be faster after changing ring & pinion ratio. At this rpm (4000+), reduced net voltage from back EMF is limiting motor current to around 300 amps.
Acceleration is 0-60 in 6.1 seconds entirely in 4th gear. Even with the stage III Kennedy clutch and non
slip ceramic disc, the clutch still slips when I floor it in 4th, so it is not performing to full
potential. If I start in a lower gear, I need to shift to 4th at some point due to the more severe back EMF with the Warp 11. I can’t shift quick enough to break 6 seconds. I expect this to improve after replacing the tranny with a 3.44 r&p and doing it in 3rd gear. I expect it to beat my other car, a VW bug which has a Warp 9 yet does 0-60 in 5.3 seconds! It will also be faster if I can prevent the clutch
from slipping. Considering a stage IV pressure plate. Also, I haven’t really dropped the hammer yet because it will probably destroy the stock tranny! Range is120 Miles (193 Kilometers) 120 miles to full discharge, 95 miles to 80% DoD and driving normal. Watt Hours/Mile 220 Wh/Mile, 190 when driving like your grandma, 220 when driving normal, and 250 when driving aggressively. All those tests were done in warm weather. In cold weather it is significantly worse.EV Miles Current:1,200 Miles (1,930 Kilometers)
Seating Capacity 2 adults, Curb Weight 2,400 Pounds (1,090 Kilograms)
Guessing Conversion Time at around 3 months for conversion, 6 months for restoration. Conversion Cost
App $16k for conversion, $4k for restoration. Additional Features are Toyota Prius throttle, Coil over rear shocks, Kennedy stage III clutch, 4 puck ceramic disc, individual volt meters on each cell,
temperature sensors for each battery pack and motor, Volante steering wheel, Home made traction bar to prevent the motor from sagging too much on heavy acceleration and possibly bending frame horns and also preventing wheel hop. Thanks Jarrod and stay tuned for the next cool Electric Vehicle!

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