2002 VW Caddy Conversion

[NIMMOEV]

Hi Folks,

I'm converting a 2002 VW Caddy van using a Nissan E-NV200 motor and inverter
I thought it quite fitting that I convert the van using an electric van drivetrain
I started working on the van a couple of months ago & have been mostly refurbishing the front end in preparation for the conversion
I've been collecting parts over the last few months or so and now I’m about ready to start doing some of the conversion work
I will keep this thread updated as I make progress but the usual obstacles like time, money and a garage that is becoming extremely difficult to heat as the Scottish winter takes hold will probably make for fairly slow progress
Here’s a few pics of the van & the progress I’ve made so far

Cheers for having a look

[Kevin Sharpe]

Great project

[Cookie6000]

I like this! It will tick sooo many boxes for anyone looking to conv mk4/5 golfs, a3's, polo's, or ibiza's! Interested to see how close to the bulkhead the motor and box end up.
Good luck on the build!

[NIMMOEV]

Great project

Cheers Kevin

[NIMMOEV]

I like this! It will tick sooo many boxes for anyone looking to conv mk4/5 golfs, a3's, polo's, or ibiza's! Interested to see how close to the bulkhead the motor and box end up.
Good luck on the build!

Cheers Cookie600,
I'm going to get the subframes back in at the weekend & get the gearbox mounted so I can start measuring up for adaptor plate
I'll post a pic so you can see the location of the motor/gearbox in relation to the bulkhead

[NIMMOEV]

Managed to get a couple of hours in the garage tonight, got the subframes and the gearbox back in place and the motor roughly in position
Really happy with how its sitting, clearance is a bit tight between the rear of the motor and the collar of the driveshaft but it should be ok
It's a pity that the motor housing has the overhang at the top to support the inverter, would have been a simpler adaptor plate design if it was a flush face but it's not that big a deal
I'll hopefully get some time during the week to better align the motor and gearbox so I can get some measurements taken

[johu]

Wow, thats what I call a clean work space I still get greasy hands when working on Touran sometimes.
If you need some inspiration for motor mounting, heres how I did it: viewtopic.php?f=11&t=32&start=40

[NIMMOEV]

Wow, thats what I call a clean work space I still get greasy hands when working on Touran sometimes.

If you need some inspiration for motor mounting, heres how I did it: viewtopic.php?f=11&t=32&start=40

After years of getting oily working on projects, it makes a nice change to be working on a clean (and green) project

Thanks for the inspiration johu, I have been following your Touran build and had been considering your design as a way forward, I've now ordered some materials & will pretty much copy your design

[NIMMOEV]

Hi guys, apologies for the lack of updates, the refurbishment of the van is taking longer than anticipated so the EV side of things has been slow.
I should be finished the worst of the refurbishment work in the next couple of weeks then I will jump back on to the conversion work.
I did get the charge port done

[jalovick]

Managed to get a couple of hours in the garage tonight, got the subframes and the gearbox back in place and the motor roughly in position
Really happy with how its sitting, clearance is a bit tight between the rear of the motor and the collar of the driveshaft but it should be ok
It's a pity that the motor housing has the overhang at the top to support the inverter, would have been a simpler adaptor plate design if it was a flush face but it's not that big a deal
I'll hopefully get some time during the week to better align the motor and gearbox so I can get some measurements taken

Had you ever considered installing the Nissan reduction gear and updating the driveshafts to fit? It does add some complexity, but you'd have a gearbox made for it.

[NIMMOEV]

I looked in to using the nissan gearbox with adapted driveshafts but it was cheaper going with an adaptor plate & coupler, if budget wasn't an issue I would have liked to go that route tho