This project consists of the following components:
* 69 beetle
* Tesla Small Drive Unit
* Elcon 3.3kw Charger ( I started out with a 10kw Tesla charger and the open source board but managed to fry the charger)
* Chevy Volt DC/DC converter
* Chevy Volt Gen 1 battery pack (16kwh)
I had the boards for both the drive unit and the charger made at JLCpcb.com using the open source files that Damien so generously provided.
Downside of the process of making the boards vs. purchasing them - I ordered 5 boards and only currently need 1.
Once I've confirmed that these boards are good, I'll be selling off the additional ones and donating the profit to Damien and Johaness for all their hard work.
1969 Beetle - Tesla Small Drive Unit
Re: 1969 Beetle - Tesla Small Drive Unit
Charger access is through the middle of the hood. The lid shown in the last photo is a 6 inch deck access port that's used in the boating industry. The lid screws in with 2 turns and can be easily reached from either side of the car. I'll be making a 3d printed replacement with vw logo.
Being tricky on this item, means I won't be charging in the rain.
Being tricky on this item, means I won't be charging in the rain.
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JaniK
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Re: 1969 Beetle - Tesla Small Drive Unit
Nice project!
Any opinions are my own, unless stated otherwise. I take no responsibility if you follow my way of doing things and it doesn't work. Please double check with someone who knows what they are doing.
Battery Placement
Battery is from a 2014 Chevy Volt. Each of the modules in the picture is 100 V. Three of these are mounted in the back and 1 upfront.
The rear luggage tray and sheetmetal were removed. I added a platform of 1" tube steel. Cardboard templating to get the sheet metal shapes right. Aluminum diamond plate is .040.
Rear side panels have been replaced with aluminum sheet.
Rivnuts are inserted into the horizontal sheet metal under the batteries. The original c-rail from the Chevy mounting plate is used on either side of the batteries. Aluminum tubes are fit in the gaps between the center battery and outer batteries. Bolting those tubes to the horizontal deck squeezes the batteries out towards the edges. I'll be fabricating a box to go over the batteries which will leave 2 "cubby" type areas available on either side for small packages, etc.
All the shiny aluminum plate will be covered with charcoal grey flocking that will give it a suede leather look.
The rear luggage tray and sheetmetal were removed. I added a platform of 1" tube steel. Cardboard templating to get the sheet metal shapes right. Aluminum diamond plate is .040.
All the shiny aluminum plate will be covered with charcoal grey flocking that will give it a suede leather look.
Battery wires
Battery cables are 2/0 welding wire. HV wires are contained within a 2" plastic conduit in the tunnel.
I drilled a 2" hole through the top of the tunnel, then welded a small section of pipe back in to reenforce the tunnel. The opposite end of the conduit comes up at the rear torsion tube.