'63 VW Transporter - EM57 Powered.

[jerrykco]

'63 VW Transporter - EM57 Powered. [WIP]
This is my new project. Finally wrapping up the '70 MGB Roadster - 2015 Leaf EM57 powered and we learned a lot!
So far just collecting parts.
● A new wire harness is on the way.
● We have the full stack Leaf EM57 motor already.
I am not sure it will fit but I am pretty sure that the Inverter and motor will.
● We just ordered a KIA EV6 / HYUNDAI Ioniq 5 EV 77KWH 800v battery.
New w/0 miles Came from cars damaged in transit.
We plan to drop the voltage in half placing half the 32 modules in parallel.
● Battery Storage
Under the bed where the gas tank is & under the rear bench seat. That is our working theory anyway.
● We plan on using the Brat VW adapter between the EM57 and the transmission.
● VW bus status.
Body panels that were rusted were replaced 5-10 years ago followed by a poor paint job.
Paint and body putty needs to be removed.
We are planning on stripping it (bead blasting) inside and out then sanding it and primed.
Followed by a new paint job before starting on the conversion.
● Questions:
1. Has anyone hacked the BMS for this battery pack?
2. Any recommendations for a VCU?
3. How about Gauges? Any ideas there?
Speedometer should still work off the transmission.
I would like an indicator for the battery condition like a fuel guage.

Love to hear your ideas and thoughts.

[jerrykco]

Now for some Pictures:
Rescuing the Transporter:

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The Battery

The EM57

[Bratitude]

.
● Questions:
1. Has anyone hacked the BMS for this battery pack?
2. Any recommendations for a VCU?
3. How about Gauges? Any ideas there?
Speedometer should still work off the transmission.
I would like an indicator for the battery condition like a fuel guage.

Love to hear your ideas and thoughts.

I am using the a leaf motor and half of one of these batteries.


Zombieverter for the stack

The bms uses a max MAX17845 chipset

Threads: viewtopic.php?t=1179

viewtopic.php?t=2243



Commercial bms master:
https://wdrautomatisering.nl/shop/gatew ... 1-gateway/

[jerrykco]

I am using the a leaf motor and half of one of these batteries.

What are you using for the BMS?
Are you cooling the batteries? (I read some concerns in the topics you shared).

[Bratitude]

What are you using for the BMS?
Are you cooling the batteries? (I read some concerns in the topics you shared).

I don’t have the battery assembled yet, but for now mounting them on a 8mm aluminum plate, which I will replace with a liquid cooling plate later on.


The stock bms slaves and the parts referenced in the threads. Likely will purchase the bms master I linked.

I will be updating my 720 build thread in a few weeks with battery progress

[ianlighting]

Hurrah! Another VW!

Seen my T2 build? There’s photos I’ve put up over the last 2 days that give you some pointers on how you can arrange the Leaf stack. Mine’s a 74, so I’m guessing I’ve got a bit more space to play with.

The engine bay had plenty of space in terms of volume, but it was really hard to find a way to use it to home all the Leaf stuff. What I came up with is the only solution that worked for me. Separated the PDM, and rotated it 90deg so it could sit slightly lower in the fuel tank space. It’s tight though, and the design on your earlier model could be different if you’re unlucky. Be interesting to see if you find another way to do it.

Also, the later T2’s had an engine inspection hatch. This has really been invaluable for me. Mounting the motor is ok, Brat adaptors are good, but for all the other wiring and coolant stuff I think i would have found it impossible without being able to look down on it and get my hands in.

viewtopic.php?t=4943&start=100

For a different take on things check out Cera’s build on her T2. Using motor direct to axle. More complex to support, but gives you more space to play with I think.

Good luck!

[jerrykco]

Seen my T2 build? There’s photos I’ve put up over the last 2 days that give you some pointers on how you can arrange the Leaf stack. Mine’s a 74, so I’m guessing I’ve got a bit more space to play with.

Checking them out, now!

[jerrykco]

Well this is discouraging.
I tried to order the Zombieverter on http://www.evbmw.com/index.php/evbmw-webshop/vcu-boards
I get this message:
Shopping Cart
Your shopping cart is empty!

[Bigpie]

It seems to be working for me. Pressing "Add to cart" and then "Checkout"

At which stage are you having issue? I notice you're not on the https site https://www.evbmw.com/index.php/evbmw-w ... vcu-boards this is likely your issue.

[jerrykco]

It seems to be working for me. Pressing "Add to cart" and then "Checkout"

Screenshot 2025-06-11 at 14.05.25.png
Screenshot 2025-06-11 at 14.05.32.png

At which stage are you having issue? I notice you're not on the https site https://www.evbmw.com/index.php/evbmw-w ... vcu-boards this is likely your issue.

Thanks Bigpie!
I used your link and it worked. Whoooo Whooooo! It's ordered!

[jerrykco]

Update: I ordered Zombiverter an June 11. I haven't received a confirmation email as of today June 14th. Is that normal?

I also ordered and received from Aliexpress https://www.aliexpress.us/item/2255801027254586.html the metal case and wire harness for the card.

Questions:
1) I think I understand but want to confirm: My first EV build used the OI board with the EM57. This time I want to use the Zombi and avoid the disassembly of the stack. Confirming that I do not need the OI board and can use the native board and control the Leaf Stack w/ the Zombi?
2) Also I want to control the Otrion BMS with Zombi. Am I missing anything?
3) Is there a preferred accelerator pedal?

[Jacobsmess]

1. Yes zombie will work with the leaf stack over CAN
2. I think Orion would need to be setup using CAN mapping. If you use the Orion to send messages on the same IDs as SimpBMS this should work but might be worth double checking
3. Any accelerator that uses a potentiometer, preferably a dual pot pedal for redundancy.