Looking for TÜV engineer to legalize conversion in South Germany

[Bintang 5]

Hi everyone,

new here and planning my first conversion, a 1985 S123 Mercedes.
Biggest challenge at the moment seems to find a TÜV engineer, who can legalize my conversion.

Local TÜV doesn't seem to be capable, referred me to the "Technischer Dienst" im Munich, who are happy to help but as it seems want an EMC inspection...

Anyone has an address / contact of a TÜV in South Germany / Baden Württemberg that has experience with conversions and do not neccessarily insist on a EMC test?
Ideally in the Bodensee region...

Thank you,
Stefan

[arber333]

Hi everyone,

new here and planning my first conversion, a 1985 S123 Mercedes.
Biggest challenge at the moment seems to find a TÜV engineer, who can legalize my conversion.

Local TÜV doesn't seem to be capable, referred me to the "Technischer Dienst" im Munich, who are happy to help but as it seems want an EMC inspection...

Anyone has an address / contact of a TÜV in South Germany / Baden Württemberg that has experience with conversions and do not neccessarily insist on a EMC test?
Ideally in the Bodensee region...

Thank you,
Stefan

Well it seems you are not asking correctly. Instead of asking: "How can i do this?" you should be telling them: "I have this done, what are the conditions to certify it?"

I have recently done it in TUV sud. But there are special conditions it appears. All the major parts i used in my conversion are regular EV parts or other car parts that already were certified to be used in EV car. If you use 3rd party stuff you will need some form of EN or CE certificate. This also applies to battery.
I suggest you get it done with some Ampera, VW or BMW battery which is certified and tested in a vehicle.
There is another aspect. I requested my TUV as a single conversion and not a serial conversion. That would require full aspect of ECE R100 standard.

I have a friend who helped me to get in touch with the right person. Maybe it would be best if you ask him.
https://www.fleck-elektroauto.de/

[Bintang 5]

I am planning to get completely rid of the original powertrain and replace it with a small Tesla drive unit.
Waiting for the open inverter Solution for Tesla Model 3...

Regarding battery, these PHEV BMW packs seem to be a good source. Did you use the complete pack or got the modules out of the pack?

Heiko Fleck is often mentioned. Yet not intending to buy anything there as I plan to use mainly used OEM parts...
Might ask him anyway.

Are EV-OEM parts automatically considered as "certified" for the use in a conversion? I don't assume you get any kind of documentation for these parts?

[arber333]

I am planning to get completely rid of the original powertrain and replace it with a small Tesla drive unit.
Waiting for the open inverter Solution for Tesla Model 3...

Regarding battery, these PHEV BMW packs seem to be a good source. Did you use the complete pack or got the modules out of the pack?

Heiko Fleck is often mentioned. Yet not intending to buy anything there as I plan to use mainly used OEM parts...
Might ask him anyway.

Are EV-OEM parts automatically considered as "certified" for the use in a conversion? I don't assume you get any kind of documentation for these parts?

Really good choice. Back when i got the Leaf motor it was really the only affordable choice here, so i went for it. Now there are more solutions available.

Yes i used complete Ampera battery with original BMS modules. I used SimpBMS as a mediator, but i figure i could make the BECM work for me also. Sadly i hadnt had the time or the will to try.

Heiko can mediate at TUV Sud. As i am not German citizen i need someone to apply for me. For a nominal fee .

As i understand Motor-inverter combination has been tested for EMC and EMI. If you use the same OEM combo you should be good. I really think guys at TUV have a database with inverter, motor, charger and DCDC part numbers which are tied to their respective EMC codes. I had to send evidence of my inverter front sticker which was not visible at the time of inspection. For charger they also demand either CE mark or OEM certificate references.
For Webasto heater they took photo of the front face with CE mark.
Brake vacuum booster needs to have a CE also.
If you use EHPAS pump you need to demonstrate it came from another vehicle. Usually a photo of part number and installation is good enough.
DCDC, well i would go for Tesla stuff any day, but Ampera DCDC was available and cheap. It has CE mark and all.
They are quite thorough. You need to have battery boxes sealed tight. Cover needs to be electrically insulated. Boxes need to have gas venting possible. Batteries need to be firmly mounted and they go about checking that for every box!
Every HV cable needs to in an orange sleeve and fixed by grommet when passing through a bulkhead.
https://leafdriveblog.wordpress.com/202 ... -findings/

[johu]

Zapatero here on the forum had his Leaf based conversion certified in Ulm. Try reaching out to him. Also read this: https://openinverter.org/wiki/Germany

I've got my two conversions certified in Göttingen but thats not quite your region

[EV_Builder]

Zapatero here on the forum had his Leaf based conversion certified in Ulm. Try reaching out to him. Also read this: https://openinverter.org/wiki/Germany

I've got my two conversions certified in Göttingen but thats not quite your region

Can you elaborate on that?

Which certification did you obtain in Göttingen ?

I'm situated in the Netherlands but i'm reading that a build made of OEM components is not accepted only a build using one complete donor vehicle...

[johu]

In bureaucratic it is called "Begutachtung gemäß §21 StVZO nach Erlöschen der Betriebserlaubnis". All other details on linked wiki page.

[mcb]

Sorry for getting a bit offtopic, but cause I'm new in here I'm not allowed (or I dont know how) to do a personal message.
Hi Bintang 5, you wrote:

... I think a Mitsubishi Outlander rear diff would fit even better than a Leaf, the "piled up" design of the Nissan Leaf Motor makes it somehow more challenging to fit under a car....

I am also from near Bodensee / RV and I've got a Outlander rear motor with Diff. which I can give away, are you interested?
My plan is to electrify an old Unimog 406, but I know its a long way to go... and any informations would be very welcome!

Kind regards
Mike