Karmann Ghia with AC-50

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Monkeytom
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Karmann Ghia with AC-50

Post by Monkeytom » Wed, 10 Feb 2016, 02:10

We bought a rough VW 71 Karmann Ghia Convertible project 12 months ago for my wife Lara she has always liked them, It came without an engine, I have been thinking EV for a while now and today we took the plunge and bought a new AC-50 with Curtis 1238-7501 kit so I am now on the look for a VW adapter and coupler if anyone has one sitting around. And so a new can of worms and our EV journey begins. Tom
Last edited by Monkeytom on Wed, 10 Feb 2016, 14:37, edited 1 time in total.
2 x PIP4048HS
15S2Px3 45x90Ah TS and
45x100Ah CALB
With 5Kw Solar Offgrid
6x175W BP 1Kw Si Offgrid
28x60W Thin film Offgrid
12x185W 2Kw Si Offgrid
48x82W gridtied CMS2000 2kw north,1Kw East,1Kw west.

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Karmann Ghia with AC-50

Post by EV2Go » Wed, 10 Feb 2016, 05:10

Looking forward to this one.

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Karmann Ghia with AC-50

Post by Adverse Effects » Wed, 10 Feb 2016, 15:05

welcome
this will be interesting

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Karmann Ghia with AC-50

Post by Monkeytom » Wed, 10 Feb 2016, 15:33

The previous owner kept the twin port engine for his Beatle project,
Lara's KG was a Slickshift type without a clutch peddle and came with the trick gear stick that you push down on to switch and operate the electro mechanical vacuum clutch, we did not get that clutch with the car but it would be a cool feature to keep.
original setup was a switch on the gear stick that operates a solenoid valve and a vacuum cylinder that operates the clutch actuator arm.
I have since purchased a std. 4 speed transaxle and clutch and may look into a solenoid actuator to operate that clutch if needed. something different.
I have purchased a set of used Thundersky 90Ah cells and a set of EV parts cell top BMS module boards and a new Delta-Q 96 volt charger its only 9 Amp but that should do an over night charge, and can plug in anywhere. I am learning quickly this all costs a bunch of our half dollars. I will look out for another 17 Thundersky 90Ah cells that will give me 60 in total and I will run 30S2P. Tom
2 x PIP4048HS
15S2Px3 45x90Ah TS and
45x100Ah CALB
With 5Kw Solar Offgrid
6x175W BP 1Kw Si Offgrid
28x60W Thin film Offgrid
12x185W 2Kw Si Offgrid
48x82W gridtied CMS2000 2kw north,1Kw East,1Kw west.

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Karmann Ghia with AC-50

Post by Monkeytom » Wed, 10 Feb 2016, 19:25

Some background on this car its a 1971 model Karmann Ghia. These are built on an air cooled VW platform although they have wider floor pans (they don't have running boards)it originally had a 50 HP Twin Port 1600cc engine with a kerb weight of 870Kg (1918Lbs) a 1600 VW Engine weighs 100Kg (220Lbs)so without engine weight 770Kg and probably another 20-30Kg can come off Air cleaner, fuel tank, ATF tank and vacuum tank, coil, Muffler and some other stuff, so total may be as low as 740Kg Now lets add some weight AC50 Motor 52Kg Curtis 1238-7601 controller with chill plate and cooling 30 Kg Battery charger and Control gear 20 Kg Adapter and coupling 10Kg and the biggie Batteries and boxes 60 90Ah Thunderskys approx. 3 Kg ea 180Kg and battery boxes 20Kg so add 312Kg and it will weigh approx. 1052 Kg (2314Lbs) 182Kg more than std.
These cars were built between 1955 and 1974 they got heavier as the years went on, in 1974 The last year it weighed 950 Kg (2094Lbs) That model was nick named The Fat Chick. Well that 74 was skinny compared to our EV we will be approx 100 Kg heavier than a 1974 KG. and close to 170Kg heavier than stock.
On HPEVS web site they claim 71 HP and 120 Foot pounds of Torque for a kerb weight auto of 1590Kg (3500Lbs) or less. so it should go OK.
http://www.hpevs.com/HPEVS-AC-Electric- ... hicles.htm
Last edited by Monkeytom on Thu, 11 Feb 2016, 13:11, edited 1 time in total.
2 x PIP4048HS
15S2Px3 45x90Ah TS and
45x100Ah CALB
With 5Kw Solar Offgrid
6x175W BP 1Kw Si Offgrid
28x60W Thin film Offgrid
12x185W 2Kw Si Offgrid
48x82W gridtied CMS2000 2kw north,1Kw East,1Kw west.

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Karmann Ghia with AC-50

Post by EV2Go » Thu, 11 Feb 2016, 14:28

Do you have any pictures of the donor?

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Karmann Ghia with AC-50

Post by Monkeytom » Fri, 12 Feb 2016, 02:07


Here is a pic of it when we first got it, it has not changed much since then. I have been buying bits for it and collecting info, it was imported from Las Vegas back in 2005 and pulled to bits to restore and left for ten years, Then we bought it. It came with a large number of rust repair panels and new floor pans, which would cost more than we paid for the car so that was good, the chassis had been removed from the car and the rusty pans removed and prepared for welding, I have since bought a mig tig welder, it will get a work out. The body has been mounted on a rotisserie to make it easier to get around, I have the parts to convert it to RHD which is very straight forward with a 1969 RHD beetle disk front end, the dash will be the hard bit. This will be my fourth car I have done from a shell, I have a 1968 firebird conv, a 1959 Chevy Impala coupe now sold, a 1959 Goggomobil Dart, and now this one. Love a challenge... Image
2 x PIP4048HS
15S2Px3 45x90Ah TS and
45x100Ah CALB
With 5Kw Solar Offgrid
6x175W BP 1Kw Si Offgrid
28x60W Thin film Offgrid
12x185W 2Kw Si Offgrid
48x82W gridtied CMS2000 2kw north,1Kw East,1Kw west.

Monkeytom
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Karmann Ghia with AC-50

Post by Monkeytom » Fri, 12 Feb 2016, 02:14

Good news my motors are on their way from the US. I ended up buying two sets AC-50 motor with Curtis controllers 1238-7501 96 volt and a Curtis pot box 6 so if you need a AC-50 setup I will have one for sale at a good price but I wont know what that is til they have landed. ETA end of April.
Image
Last edited by Monkeytom on Sun, 21 Feb 2016, 07:00, edited 1 time in total.
2 x PIP4048HS
15S2Px3 45x90Ah TS and
45x100Ah CALB
With 5Kw Solar Offgrid
6x175W BP 1Kw Si Offgrid
28x60W Thin film Offgrid
12x185W 2Kw Si Offgrid
48x82W gridtied CMS2000 2kw north,1Kw East,1Kw west.

Monkeytom
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Karmann Ghia with AC-50

Post by Monkeytom » Fri, 12 Feb 2016, 02:25

I picked up these batteries for a good price, There was 43x90Ah I bought two new ones today to bring the pack up to 45, and I will lookout for another 15. I would like to go 30S2P in the car and I will go 15S3P on my 48 volt off grid PIP4048 system in the mean time, I have also bought a set of EV-parts cell top bms modules for them. and a couple of solid state relays to try as a pack disconnect on the Off Grid System.
Image
Last edited by Monkeytom on Thu, 11 Feb 2016, 15:53, edited 1 time in total.
2 x PIP4048HS
15S2Px3 45x90Ah TS and
45x100Ah CALB
With 5Kw Solar Offgrid
6x175W BP 1Kw Si Offgrid
28x60W Thin film Offgrid
12x185W 2Kw Si Offgrid
48x82W gridtied CMS2000 2kw north,1Kw East,1Kw west.

Monkeytom
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Karmann Ghia with AC-50

Post by Monkeytom » Fri, 12 Feb 2016, 02:33

we are hoping it will turn out something like this one. Although Larz is still struggling to pick a colour, she has plenty of time yet.
Image
Last edited by Monkeytom on Thu, 11 Feb 2016, 15:39, edited 1 time in total.
2 x PIP4048HS
15S2Px3 45x90Ah TS and
45x100Ah CALB
With 5Kw Solar Offgrid
6x175W BP 1Kw Si Offgrid
28x60W Thin film Offgrid
12x185W 2Kw Si Offgrid
48x82W gridtied CMS2000 2kw north,1Kw East,1Kw west.

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Karmann Ghia with AC-50

Post by reecho » Fri, 12 Feb 2016, 15:24


Monkeytom
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Karmann Ghia with AC-50

Post by Monkeytom » Fri, 12 Feb 2016, 18:17

Yes that's a really nice kit and it seems to go well, the EV west conversion pushed me over the edge on the HPEVS AC-50 Kit,
EV West has a really nice billet Adapter and alloy controller mount and chill plate. I may yet buy. it sure makes for a tidy conversion.
2 x PIP4048HS
15S2Px3 45x90Ah TS and
45x100Ah CALB
With 5Kw Solar Offgrid
6x175W BP 1Kw Si Offgrid
28x60W Thin film Offgrid
12x185W 2Kw Si Offgrid
48x82W gridtied CMS2000 2kw north,1Kw East,1Kw west.

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reecho
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Karmann Ghia with AC-50

Post by reecho » Sun, 14 Feb 2016, 04:03

Monkeytom wrote: Yes that's a really nice kit and it seems to go well, the EV west conversion pushed me over the edge on the HPEVS AC-50 Kit,
EV West has a really nice billet Adapter and alloy controller mount and chill plate. I may yet buy. it sure makes for a tidy conversion.


Yes the Karmann's really deserve a top notch looking conversion. Smooth to drive even with ICE....Couldn't imagine how nice they will be with AC... Image

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Karmann Ghia with AC-50

Post by Monkeytom » Sun, 14 Feb 2016, 14:50

Thanks for posting this, It does not show a pre-charge resister circuit
Are they not required with this Curtis 1238 inverter/controller?
Anybody here using an AC-50 setup?
2 x PIP4048HS
15S2Px3 45x90Ah TS and
45x100Ah CALB
With 5Kw Solar Offgrid
6x175W BP 1Kw Si Offgrid
28x60W Thin film Offgrid
12x185W 2Kw Si Offgrid
48x82W gridtied CMS2000 2kw north,1Kw East,1Kw west.

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Karmann Ghia with AC-50

Post by g4qber » Wed, 17 Feb 2016, 06:38

http://youtu.be/c5ftvj0HO-U

Karmann ghia conversion by ev west finished
Last edited by g4qber on Tue, 16 Feb 2016, 19:38, edited 1 time in total.
2011 i-MiEV - 139 kms May 2018

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Karmann Ghia with AC-50

Post by reecho » Wed, 17 Feb 2016, 20:37

Monkeytom wrote:
Thanks for posting this, It does not show a pre-charge resister circuit
Are they not required with this Curtis 1238 inverter/controller?
Anybody here using an AC-50 setup?


Think it's internal....but certainly do your own checks...

Contact EV West direct maybe...??

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Karmann Ghia with AC-50

Post by evric » Wed, 17 Feb 2016, 20:57

This says that the Precharge cct is built into the controller

http://www.evwest.com/catalog/product_i ... cts_id=103
Last edited by evric on Wed, 17 Feb 2016, 09:58, edited 1 time in total.
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Karmann Ghia with AC-50

Post by Monkeytom » Tue, 22 Mar 2016, 21:44

Well a quick update I have been buying more stuff.
I got a QuiQ charger and some contactors and a set of 350A Anderson connectors
2 x PIP4048HS
15S2Px3 45x90Ah TS and
45x100Ah CALB
With 5Kw Solar Offgrid
6x175W BP 1Kw Si Offgrid
28x60W Thin film Offgrid
12x185W 2Kw Si Offgrid
48x82W gridtied CMS2000 2kw north,1Kw East,1Kw west.

Monkeytom
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Karmann Ghia with AC-50

Post by Monkeytom » Tue, 22 Mar 2016, 21:51

And some more batteries, 45 x Blue 100Ah CALB cells .
turns out they are the same size as the Thundersky 90Ah cells only 7mm thicker so I will stack 5 of each in a stack of 10 cells that will give me 9 stacks and 3 x 48 volt packs two for the Karmann Ghia and one for the house battery. I do need a replacement Blue 100Ah calb cell if anybody has a spare good one thanks Tom
2 x PIP4048HS
15S2Px3 45x90Ah TS and
45x100Ah CALB
With 5Kw Solar Offgrid
6x175W BP 1Kw Si Offgrid
28x60W Thin film Offgrid
12x185W 2Kw Si Offgrid
48x82W gridtied CMS2000 2kw north,1Kw East,1Kw west.

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Karmann Ghia with AC-50

Post by Adverse Effects » Wed, 23 Mar 2016, 01:03

Image Image its an addiction

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Karmann Ghia with AC-50

Post by Monkeytom » Mon, 04 Apr 2016, 15:01

Yes it sure is,
I have stacked and clamped into groups of 10 cells 5 of each in parallel then 3 stacks = 48Volts, I have cleaned terminals and battery links and assembled with Aluminox Electrical joining paste, will use two of these in series for 96 volt car battery which I can split in two with Anderson connectors and charge on the house system and we will have one set at the house. I still need to wire BMS daisy chain.
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Last edited by Monkeytom on Mon, 04 Apr 2016, 05:04, edited 1 time in total.
2 x PIP4048HS
15S2Px3 45x90Ah TS and
45x100Ah CALB
With 5Kw Solar Offgrid
6x175W BP 1Kw Si Offgrid
28x60W Thin film Offgrid
12x185W 2Kw Si Offgrid
48x82W gridtied CMS2000 2kw north,1Kw East,1Kw west.

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Karmann Ghia with AC-50

Post by evric » Mon, 04 Apr 2016, 20:49

Hi Tom,
That looks really good.
How are you holding / bolting the cells down?
Eric
Prius Plug-in Conversion: http://www.evplus.com.au ...Holden Barina EV: http://www.evric.kestar.com.au

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Karmann Ghia with AC-50

Post by Monkeytom » Wed, 06 Apr 2016, 02:35

Thanks Eric, The yellow cells are Thundersky 90Ah and the Blue ones are CALB 100Ah, I have cut some thick Formica sheet, Like used on counter tops in years gone by. For the end plates and clamped the cells together with 4 6mm threaded rods with some U shaped steel across the formica. Each stack of 10 cell will sit in an angle iron frame But that's as far as I have got so far. I am currently testing each cell for capacity, Charge, measure discharge, then Charge and measure discharge and charge again so will do each twice.
2 x PIP4048HS
15S2Px3 45x90Ah TS and
45x100Ah CALB
With 5Kw Solar Offgrid
6x175W BP 1Kw Si Offgrid
28x60W Thin film Offgrid
12x185W 2Kw Si Offgrid
48x82W gridtied CMS2000 2kw north,1Kw East,1Kw west.

Monkeytom
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Karmann Ghia with AC-50

Post by Monkeytom » Sat, 24 Sep 2016, 21:07

A bit of an update, well I sold my second motor so that freed up some funds to keep the project moving forward,
I purchased a charger discharger to test all my used cells and they are testing as well as I expected, most of my second hand six years old ebay purchase thundersky 90Ah cells are measuring at between 80/82Ah capacity when charged to 3.7 and discharged to 2.9 at a 10 Amp load for the discharge.
And the six year old CALB 100Ah are testing at 81/83Ah capacity when charged to 3.7 volts and discharged to 2.9 volts at a 10 Amp load for the discharge.
So I am more than happy with my $4000 LiFePo4 battery 23KWh and usable to 80% of 18 KWh which will be 12KWh in the car and 6 KWh on the Off Grid system.
The Off Grid system is one year old next month it has changed a lot over that year but it's going great, it went from a single PIP4048HS on Lead acid, and is now 2x PIP4048HS inverters with 18KWh LiFePo4 battery 5 1/2 KW solar it has saved me $2210 to date. And should have paid for it self inside three years total.
I have also purchased a couple of AC to DC96Volt chargers to fit in the car so the car can be charged when we are out.
The car battery will be 2 x 48 Volt packs joined in series with a pair of 350 Amp Anderson connectors to run the AC50 at 96 volts and when we get home the battery can be split into 2 X 48volt batteries and charged in parallel when hooked to the Off Grid system with 175 Amp Anderson connectors for solar charging or increasing the home battery capacity.
I have also purchased an Alloy adaptor plate VW flywheel clutch and pressure plate, the Adaptor plate is for a Chev Corvair flat 6 to VW Trans, so it will need some mods but will do the job fine it will need a new spacer turned up from alloy to go between the motor and Adaptor to get the spacing right but I will have to wait till the flange coupler I have purchased arrives to get the measurement for the spacer. Tom

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Image
Last edited by Monkeytom on Sat, 24 Sep 2016, 12:03, edited 1 time in total.
2 x PIP4048HS
15S2Px3 45x90Ah TS and
45x100Ah CALB
With 5Kw Solar Offgrid
6x175W BP 1Kw Si Offgrid
28x60W Thin film Offgrid
12x185W 2Kw Si Offgrid
48x82W gridtied CMS2000 2kw north,1Kw East,1Kw west.

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Karmann Ghia with AC-50

Post by Monkeytom » Sat, 24 Sep 2016, 21:49

Having trouble uploading pics
Last edited by Monkeytom on Sat, 24 Sep 2016, 11:56, edited 1 time in total.
2 x PIP4048HS
15S2Px3 45x90Ah TS and
45x100Ah CALB
With 5Kw Solar Offgrid
6x175W BP 1Kw Si Offgrid
28x60W Thin film Offgrid
12x185W 2Kw Si Offgrid
48x82W gridtied CMS2000 2kw north,1Kw East,1Kw west.

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