Project VW Cadd-E, Leaf/Volt/Mercedes + Mk1 VW

tom91 · Post by **tom91** » Wed Aug 24, 2022 3:01 pm

I hate to burst your bubble, or atleast here in the UK a BMW hybrid pack can be had for 1K gbp at 12 kwh, the older lower voltage 7kWh can be had for under 800gbp. So that makes building modules yourself alot of work.

However it all depends on what you want to gain from a project. I am glad you managed to get through all the little problems you had.

vwbrady · Post by **vwbrady** » Wed Aug 24, 2022 7:41 pm

I'm happy to be "done" with this part of the journey! No bubbles have been burst as the battery market here just isn't that great.

The BMW pack is a great option, however finding the 12kWh packs for $1k just isn't possible here. I did buy 6 individual 2kWh modules for $1700, which was a good deal though they did not come with the BMS

. Those will be for some other project.

The cheapest 12kWh BMW pack is in Las Vegas for $1200. with tax and shipping that'd be about $2k. Then I'd have to make some kind of enclosure for them, which the Merc batteries didn't need, then adding your $500 BMS on top of that. I know it's 5 more kWh, but it's not that obvious of a choice for my specific project goals.

I keep my eye out for good EV battery options mostly from batteryhookup.com, but if I can get my hands on a $100/kWh BMW pack, i take it.

RetroZero · Post by **RetroZero** » Wed Aug 24, 2022 8:14 pm

Thanks heaps for that break down on prices. I'm in a similar boat, where batteries are not 'sold' on an open market. So getting some 'faulty' modules to play around with means major time spent adapting it all. You did it, so it's possible, but I didn't realise how much time went into that part of your project. Bravo

vwbrady · Post by **vwbrady** » Sun Aug 28, 2022 5:57 pm

L1 charging at 1300W!

Volt charger being controlled by a simple pwm generator

vwbrady · Post by **vwbrady** » Tue Aug 30, 2022 8:00 pm

On my way to being a YouTube star like everyone else. It's a good medium for documentation though.

vwbrady · Post by **vwbrady** » Fri Feb 03, 2023 7:20 pm

It's been a while! I guess that happens when you reach the "road-worthy" milestone.

This truck has just worked... It's easily my most reliable, non-modern, car I own. This past summer I nearly drove it everyday including a few 40mi trips on i-5 down to Seattle. It even does truck stuff like haul refrigerators!

I picked up a matching 1980 4dr Rabbit, that will be getting a model 3 drive unit.

replaced the windshield and back glass along with some minor rust repair

New Corrado Wheels

moved the simp BMS display to the dash, but have yet to get it to control the charger

truck things:

Bratitude · Post by **Bratitude** » Thu Feb 09, 2023 12:48 am

vwbrady wrote: ↑Fri Feb 03, 2023 7:20 pm

This truck has just worked... It's easily my most reliable, non-modern, car I own. This past summer I nearly drove it everyday including a few 40mi trips on i-5 down to Seattle. It even does truck stuff like haul refrigerators!

isnt it so awesome? it all just...works....so much so you forget what went into it..

vwbrady wrote: ↑Fri Feb 03, 2023 7:20 pm
I picked up a matching 1980 4dr Rabbit, that will be getting a model 3 drive unit.
PXL_20230121_000028363.jpg

note on the m3 drive units, from what i can tell, the drive shaft stubs between the m3/y and s/x are the same other than the seal od. so looks like you can swap s/x seal on to your m3 drive unit and use the zero ev/ ev west adapter stubs

vwbrady · Post by **vwbrady** » Sat Feb 11, 2023 4:15 pm

Bratitude wrote: ↑Thu Feb 09, 2023 12:48 am isnt it so awesome? it all just...works....so much so you forget what went into it..

The relative simplicity of the EV system I think contributes the most. After this winter I needed to move some cars around and after not touching this truck for months I turned the key to see what would happen. I was greeted by the water pump turning on followed by that sweet sweet contactor 'click' and away it went.

Bratitude wrote: ↑Thu Feb 09, 2023 12:48 am note on the m3 drive units, from what i can tell, the drive shaft stubs between the m3/y and s/x are the same other than the seal od. so looks like you can swap s/x seal on to your m3 drive unit and use the zero ev/ ev west adapter stubs

I have seen the Zero EV stubs and they look pretty nice! Fortunately, I have the entire front and rear subframe along with all suspension and axles. so being cheap I'll probably just adapt the axles to one another at first. Having the axles I may also find time to model up my own stub for m3/y to VW. We'll see.

Bratitude · Post by **Bratitude** » Sat Feb 11, 2023 11:40 pm

vwbrady wrote: ↑Sat Feb 11, 2023 4:15 pm I have the entire front and rear subframe along with all suspension and axles. so being cheap I'll probably just adapt the axles to one another at first. Having the axles I may also find time to model up my own stub for m3/y to VW. We'll see.

id recommend turning down the tripod joint and welding on a flange with the 100mm/108mm bolt pattern.
similar to this:

im probably another 6months away from having tesla to vw stubs (like my leaf ones) available

vwbrady · Post by **vwbrady** » Sat Jun 15, 2024 9:01 pm

For anyone curious, the truck has been one of my most reliable vehicles! I can let it sit all winter and come spring time, it just WORKS. Only downside is the ≈7.5kWh I put in it, which gets me about 45 miles. I already have a set of BMW hybrid modules that make up a 12kWh pack that I plan on installing sometime in the future. But as is, I can get to work and back and go anywhere in town easily.

I do only have the option of charging at L1 chargers, which limited out in the wild, but it hasn't been so bad. Next conversion will include CCS1

I have other EV conversions in mind that I'll be slowly collecting parts for. Until then, Here are some of the rabbit pickups adventures: