New Page 1Electric Vehicle Kit - VWVW Electric Vehicle
Electric VehicleConversion Kit VW Bug Frame
Introduction
This is an electric vehicle conversion kit with the essentialparts needed to make your car run on electricity. This kit can be installed inone day if you have a little mechanical experience. It is designed to work on aVW bug standard transmission, and will work with any air cooled VW based frameor kit car from 1952 to 1979. Automatic VWs are not recommended with use of thiskit. This kit is designed to be clutchless with the VW, but you still do shiftby just letting off of the throttle pedal when shifting. After installed, the VW will get top speeds of 45-55 MPH once the batteriesand motor are worn in and will get a range of 15-40 miles according to drivinghabits, etc. Average range would be 25 to 30 miles on a charge once everythingis worn in, but this all depends on what batteries you use and how many, etc. The parts included in this sale are: (#1) Permanent Magnet DC motor measuring8 in diameter x 7.42 inches long. (#2) An adaptorplate that matches the VW standard transmission to the permanent magnet motor. (#3) A shaft coupler that couples the electric motor to the transmission outputshaft. (#4) A motor controller by Kelly Controllers model # KDZ-72400 (72 volts 400 amps). (#5 )A throttle pedal that wires directly to the controller.
#1 Permanent Magnet DC Motor
The ME1003 has a double brush set to handle 200 amps continuous. This ME1003is a Brush-Type, Permanent Magnet DC motor with very high efficiency. Forvoltages from 12 to 72 VDC input and 200 amps continuous (500 amps for 1 minute)@ 72 Volts. It is rated at fifteen Horse-Power continuous and thirty HP Peak at72 VDC. Electric cars are driven by large electric motors usually rated between3.5 and 28 horsepower. For those accustomed to gas engines, this may not seemlike much power, but the rating systems used for gas engines and electric motorsare so different that the numbering system is almost meaningless. Gas enginesare rated at their peak hp, electric motors are rated at their continuous hp.The peak hp of an electric motor is usually 8 to 10 times its continuous rating.A 30 hp electric motor will generally perform like a 50-75 hp gasoline engine ina same weight vehicle. This kit has no clutch so it can simply be driven justlike an automatic transmission.
Motor Stats
Power 11.5KW continuous,
23KW Peak for 1 minute @ 72Volts
Voltage 12-72 Volts
Speed 3050 rpm at 72V Unloaded
Size 8\" OD, 7.42\" long (w/o shaft)
Shaft 7/8\"x 1-5/8\", 3/16\" key
Weight 38 lbs.
#2 Adaptor Plate
The adaptor plate is bolted to the electric motor with four1\" x 3/8 \" bolts. It matches the bell housing of the VW standard transmission.It’s made from mig welding 1/4\" steel plate.
#3 Coupler
Theshaft coupler is what slides onto the electric motor which uses your clutch discfrom your VW. Your clutch disc, which is your splined piece, is bolted to thiscoupler with 8 hardened allen screws provided. This is what then slides ontoyour transmission shaft of your VW. Depending on whether you rivet holes arelarge enough on your clutch disc (different brands) will determine if you haveto drill them bigger or not for attaching it to your shaft coupler. When themotor, adaptor plate and coupler are assembled together, the unit can then beslid onto the transmission, with four bolts to the transmission housing, and themechanical work is finished. This part can literally be done in a very short time.There is a 3/16 keyway that is 2 ½\" long with a 1/4\" allen set screw on thecoupler. These couplers are machined in a lathe made with industrial gradesteel.
#4 Controller
Included in this kit is a state-of-the-art PWM (pulse widthmodulation) MOSFET (metal oxide semiconductor field effect transistor). Thesecontrollers, Model # KDZ-72400, are made by Kelly Controller and are built with regenerative braking feature. This feature is possible because of the permanent magnet motor included in this kit. Regenerative braking can increase your range up to 25% in hilly areas. These controllers are fullyprogrammable. You can even monitor the motor parameters while driving using alaptop computer. For more information and software see their website.
#5 Throttle Pedal
Also included in this kit is a hall-effect sensor type throttle pedal assembly thatwill work with the Kelly Controller. It is mountedwere the foot pedal goes in your VW and wires directly to the controller.
General Information
General assembly instructions and wiringdiagrams for this kit is included with this sale. We have built many electric cars, so any or all questions are welcomed.
Other parts needed to complete an electric vehicleconversion that are not included in this sale:
Your VW Clutch Disc
Batteries
Cable
Meters
Amp Shunt
Contactor
Battery Boxes
Chargers
Small Wire
Bolts & will consist of two to three separate packages being sent to you ifyou offer on this sale. The motor will be dropped shipped by themanufacture. A tracking number will be sent for the other package(s) sentto you. It could be up to 10 to 15 business days before items are shipped, but parts are shipped as soon as they can be shipped.Thank you.
Waiver Of Liability & Indemnification
It is the responsibility of the component/ publication purchaser to befamiliar with the safe and correct installation and operation for all equipment.The seller has no opportunity to supervise the application, installation, ormaintenance of the components used, nor to supervise and inspect the design andmanufacture of electric vehicles in which they are used. Therefore, thepurchaser agrees by placing a winning offer and accepting deliver of componentsand material for electric vehicle usage, that all material and procedures willbe used solely at the purchaser’s risk. The purchaser will indemnify and holdthe seller, its owners, and its employees or representatives free and harmlessfrom all loss, liability, or damage resulting form the alleged failure or defectof any project built using components or publications purchased from the seller.
