Smokinjoe's Beetle conversion

Post up a thread for your EV. Progress pics, description and assorted alliteration
Klemmy
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Re: Smokinjoe's Beetle conversion

Post by Klemmy »

smokinjoe wrote: Sun, 01 Nov 2020, 10:07
So what are you using to couple the Leaf motor to the VW transaxle? I have a Sterling ( in Australia, it's the Eureka) that i'm going to convert over to electric.
Hi Klemmy,
I've just seen your post haven't been online for a while. I wish I had photos of it, I basically had the input of the Nissan leaf reduction unit machined so the clutch centre from the beetle would press in. then I tack welded it to stay there. there is a pilot bearing in the middle of the coupler to keep it centred.

[ Edited Coulomb: fixed quoting (first tag should not have the slosh character). ]
hmm good thing I do have reduction unit laying around. I have alot of other things to get through before that, thanks for the info though, it helps.
smokinjoe
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Re: Smokinjoe's Beetle conversion

Post by smokinjoe »

Spent a bit more time on the beetle this weekend, wired in the 240v charge inlet and interlock to prevent driveway, and plumbed in a small radiator to keep the whole lot cool. Just have to secure some of the wiring and i'm all finished in there.
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brendon_m
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Re: Smokinjoe's Beetle conversion

Post by brendon_m »

Nice, liquid cooled beetle :mrgreen:

I assume there was no neat way of using the original beetle fill port for the power inlet?
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jonescg
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Re: Smokinjoe's Beetle conversion

Post by jonescg »

Looks awesome mate! Hope to see it at a meeting, or at the very least Electrikhana 2021!
AEVA National Secretary, WA branch chair.
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Adverse Effects
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Re: Smokinjoe's Beetle conversion

Post by Adverse Effects »

the full conversion looks so neat
If you don't have time to do it right,
When will you have time to do it over

Help those who help themselves first
smokinjoe
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Re: Smokinjoe's Beetle conversion

Post by smokinjoe »

jonescg wrote: Mon, 23 Nov 2020, 10:42 Looks awesome mate! Hope to see it at a meeting, or at the very least Electrikhana 2021!
Thanks Chris, I'd love to get it up there for electikhana. Hopefully it's all finished by then.
brendon_m wrote: Mon, 23 Nov 2020, 05:41 Nice, liquid cooled beetle :mrgreen:

I assume there was no neat way of using the original beetle fill port for the power inlet?
Cheers Brendan, I was hoping to put it there but it would be a tight fit and I was a bit worried about the weather getting in.
Ctwidle
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Re: Smokinjoe's Beetle conversion

Post by Ctwidle »

I’ve been lurking for a while now but it’s time to get serious. I’ve just taken over a stalled 72 Super Beetle project. It’s supposedly complete but stripped to the last nut and bolt but in boxes with everything bagged and tagged.
It has IRS but I know the gearbox/transaxle needs a complete rebuild. Smokinjoe points out that the Leaf unit would require a modified firewall if it were to be kept as one piece. Here’s my first silly question (there will be more) does the Leaf unit have to be run in its original attitude? If it were run horizontal with the transaxle to the front might it be possible to fit it under the firewall? Not recommended with a regular ICE due to problems with lubrication but does anyone perceive any such problem with the Leaf?
Chris
francisco.shi
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Re: Smokinjoe's Beetle conversion

Post by francisco.shi »

I don't think it will make any difference. Most diffs' lubrication is by splashing the oil around. So as long as the main gear is touching the oil it should be fine. If you want to be absolutely right you can open the gearbox and check if it has a pump. If there is a pump you just need to make sure it can pick up the oil in the new orientation.
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brendon_m
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Re: Smokinjoe's Beetle conversion

Post by brendon_m »

It will also probably have oil sprayers on the stator for cooling, along with little catch cans for the oil to drip into certain places which may require gravity to get the oil to the right parts. That's being said, I tend to agree with @francisco.shi, there should be enough oil splashing around to make the diff work fine but ideally you would want to see one in pieces especially if theres an oil pump for the cooling side of things (which Im pretty sure there is)
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Re: Smokinjoe's Beetle conversion

Post by francisco.shi »

The motor is water cooled. It has separate cooling for the motor and the motor and gearbox are sealed separately.
A friend is using a leaf motor for a conversion and the gearbox is sealed from the motor.
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brendon_m
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Re: Smokinjoe's Beetle conversion

Post by brendon_m »

Ah yes of course. The motor splits off the gearbox easily so it wouldn't use the same cooling system
Ctwidle
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Re: Smokinjoe's Beetle conversion

Post by Ctwidle »

Thanks guys, I’ve been looking at the Performance EV videos on cramming a leaf unit into a 911 Porsche and while he might be avoiding engineering certification problems by not cutting into the structure I think that in Qld I would probably still need to consider this for the motor mounts. Adapting half shafts between the Leaf and Beetle rear ends doesn’t look like it’s too much of a problem.
At least a year’s worth of basic work to do yet on the rebuild while looking at the conversion options but it’s nice to know that this forum is supportive. I’ve just spent a happy 4 years rebuilding a ‘54 MG TF and couldn’t have done it without the help of the forums. I suppose I should start my own thread now that I have dipped my toes in the water so to speak and declared my intention to do the conversion.
Regards to all for the festive season,
Chris
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brendon_m
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Re: Smokinjoe's Beetle conversion

Post by brendon_m »

Ctwidle wrote: Sun, 13 Dec 2020, 05:21 I suppose I should start my own thread now that I have dipped my toes in the water so to speak and declared my intention to do the conversion
Chris
That was the hardest part for me, telling the internet I was planning on doing something...
smokinjoe
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Re: Smokinjoe's Beetle conversion

Post by smokinjoe »

I can confirm the reduction unit is splash lubricated, I found an old photo of when I first split the motor, gearbox and charger, not the best photo but you get an idea of orientation. Best of luck with the super beetle Ctwidle.
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