BMW I3 2019 conversion to VW Kombi 1974

[KobusI3toKombi]

Hi There!

I'm new to the forum. Thanks everyone for sharing information so freely and creating this community, I am going to need it...
This is a first attempt at a conversion like this.
My project is just in its initial planning stages, and any input would be appreciated. I have a 1974 VW Kombi that I am planning to restore and convert to electric. For this I purchased and accident damaged 2019 120Ah REX BMW I3 on auction. I am hoping to use as many parts of the I3 as possible in the conversion, and modernise the safety and comfort of the VW to as close as possible to the standards of the I3. The plan is to use this as an everyday commuter vehicle for myself, and the occasional family trip. Charging mostly off solar at home with public infrastructure only used on rare occasions. It would be great to use the REX when needed.

I'm not an engineer, but am practical and creative and an owner of a Special effects company in Cape Town South Africa, with access to a well equipped workshop and skills where I will do the project over a time frame of maybe 5 years if possible.

Will post pictures as I go and most likely ask totally cringeworthy questions.

Here we go!

[Knulen]

I love to see how your project will go. I'm also curious if your i3 currently is running, because I see a lot of wrecked i3's which don't run because of some crash sensors or something have activated some kind of protection in the system. I'm curious if yours have the same and how you have or will fix this.

[DaveH]

This is going to be a really interesting project. The i3 drive system is very good and should work well if you can both fit it in and communicate with it. I have both an i3s and a VW bus. Good luck with it!

[KobusI3toKombi]

I love to see how your project will go. I'm also curious if your i3 currently is running, because I see a lot of wrecked i3's which don't run because of some crash sensors or something have activated some kind of protection in the system. I'm curious if yours have the same and how you have or will fix this.

Thanks Knulen. Will update as I go. Started by stripping the VW and I3, but decided to just do some more research before I get carried away. Had a very informative chat to Janosch Opperman last week to talk through my plans, so I feel a lot more confident about the route forward. Thanks Janosh! Ordered the I3 OI board and a Zombiverter VCU. Next step is to get the motor out and start working towards a bench test as a first target. May be a couple of months before I get the time to get properly stuck in.

[KobusI3toKombi]

This is going to be a really interesting project. The i3 drive system is very good and should work well if you can both fit it in and communicate with it. I have both an i3s and a VW bus. Good luck with it!

Thanks! Appreciated. Fingers crossed.

[T1Terry]

I see you have an early bay window Kombi, the steps at the front doors and the indicators low set give it away.
Are you planning to replace the gearbox with the i3 transaxle and not using the petrol engine?

T1 Terry

[ianlighting]

Good luck. Any progress on your design? I’m working on a T2 aswell.

I’m not Uber geeky on this, but I thought early bays, with the low indicators stopped before 1974?

[KobusI3toKombi]

Thanks. Yes, making progress. The pictures above are not the actual Kombi- Its what I am aiming for. Here's the actual vehicle. Stripped and at a brake specialist. Starting with that before I fit the motor. Have fitted to OI. board and will hopefully soon get closer to a bench test of the motor.

I see you have an early bay window Kombi, the steps at the front doors and the indicators low set give it away.
Are you planning to replace the gearbox with the i3 transaxle and not using the petrol engine?

Planning to use the transaxle with new custom driveshafts, nothing from the Kombi

[ianlighting]

How far have you gone with your battery ideas? What capacity and where will you put them?

I had hoped to get the 60kWh for my T2 under the bench seat, but takes too much room, so having to split it.

[KobusI3toKombi]

How far have you gone with your battery ideas? What capacity and where will you put them?

I had hoped to get the 60kWh for my T2 under the bench seat, but takes too much room, so having to split it.

I'm planning to use the battery from the I3 as is- 120Ah. Looks like it may fit under the kombi similar to how it was in the I3. Some structural changes would be necessary of course, and I may need to raise the suspension a little and go for slightly larger wheels to make up for the loss in ground clearance a little. Not 100% sure yet, but will update once it starts to make sense.

[ianlighting]

I'm planning to use the battery from the I3 as is- 120Ah.

Some structural changes would be necessary of course,

So is the regulation in SA pretty relaxed? UK / Europe would not allow structural changes to the car. I expect you’ve already checked this, but just in case, it might be worth double checking any rules that might apply.

I’m guessing your 40kWh battery might give you around 140 miles range?

[Jacobsmess]

I’m guessing your 40kWh battery might give you around 140 miles range?

I think it will.be lower than this, some EV converted cars get around 3miles/kWh.
In my t5 working to around 2.3-2.5miles/kWh.

[ianlighting]

I think it will.be lower than this, some EV converted cars get around 3miles/kWh.
In my t5 working to around 2.3-2.5miles/kWh.

Maybe I’m being too optimistic on my T2 /60kWh build then I’ve said maybe 200 miles. I better start saying 150.

[KobusI3toKombi]

So is the regulation in SA pretty relaxed? UK / Europe would not allow structural changes to the car. I expect you’ve already checked this, but just in case, it might be worth double checking any rules that might apply.

I’m guessing your 40kWh battery might give you around 140 miles range?

Yes, rather than relaxed, maybe not as competent as EU perhaps. I will check before I make any changes, and have involved a structural engineer to talk it through. As far as HV components go, our authorities are still living in 1985, so safety standards will be better upheld by myself than them.

[Gregski]

jon-stewart-eat.gif (378.71 KiB) Viewed 362 times

maybe you will find this video interesting, he is wiring up the Dilithium BMS for his BMW i3 battery pack