Vito Touring

[pcfmuser]

Hi

I have a 2005 Vito, had it from 'new'. It was a showroom demonstrator and now has less than 90k on the clock. I want to convert it to a tourer. So I would like the steer from the group to explore conversion options. I was asked to share info about the current drive train (2148 cc diesel with auto trans), realistic range requirements (always negotiable), your skill level/facilities (ex mechanic and trained electrician with two professional engineering mates with their own garage, welding kit, ramps etc), and budget (always negotiable).

OK, where can we start, please?

Cheers


M.

[Kevin Sharpe]

OK, where can we start, please?

Welcome to the forum

Can you add your location to your profile? This helps us give relevant advice.

It would help if you could give us a link to the Vito Touring specs and let us know if it's FWD, RWD, or AWD.

With regards to range can you narrow it down a bit so we don't waste time suggesting solutions that won't work for you? 50 miles, 100 miles, 200 miles, more than 200 miles? Is this range requirement loaded or unloaded? If loaded, what weight is it carrying?

[pcfmuser]

Thanks a million for the reply and looking forward to learning from the knowledge of the forum.

• I'm in NW England. So lots of spare parts around and about, which is good.

• The specs of the 111Cdi Vito: https://www.car.info/en-se/mercedes-ben ... 1703/specs

• Regarding range: Ideally between 150 and 200 really.

• Kerb weight unloaded is 1818kg (with that big diesel engine) but I expect normal touring weight with all the touring internals will not exceed 2300kg.

Just trying to make the dream happen =)
https://en.wikipedia.org/wiki/Mercedes- ... opolo1.png

[Kevin Sharpe]

The specs of the 111Cdi Vito: https://www.car.info/en-se/mercedes-ben ... 1703/specs

So, it's a RWD 109hp diesel which is no problem for an EV conversion

I'd recommend the Lexus GS450H CVT and Prius Gen 3 inverter as your first option. This gets rid of the existing transmission and you'll have the BEXUS conversion to follow (here).

A second option would be a Siemens 1PV5135 motor and Prius Gen 3 inverter. This would require a manual transmission swap (don't make the mistake of assuming automatic will work) and you'll have the LandYacht conversion to follow (here).

Regarding range: Ideally between 150 and 200 really.

I'd recommend the Tesla model 3 battery modules if you can get them to fit in the rear of the vehicle easily (3D models in the wiki). These will give you the range you're looking for and are by far the cheapest option available. An alternative at twice the price is the Tesla Model S/X battery modules which could be distributed easily between the front engine compartment (which is almost empty if you use the GS450H CVT) and under the rear floor.

For the Charger/DCDC use the Tesla Model 3 PCS.

For rapid charging use the Tesla Model 3 CCS connector and charge port ECU.

Kerb weight unloaded is 1818kg (with that big diesel engine) but I expect normal touring weight with all the touring internals will not exceed 2300kg.

We need to verify the maximum weights per axle but I don't think this will be an issue.

Just trying to make the dream happen =)
https://en.wikipedia.org/wiki/Mercedes- ... opolo1.png

Dreams are welcome on this forum

[pcfmuser]

Thanks again for a smashing reply. 2 things please:-

1. what is the calculation to determine the battery and motor required for a specific range if the weight of the vehicle did increase?
2. presumably there are more parts needed to actually bolt all this gear together - are they all available on the openinverter.org Shop?

Thanks a million again for a great resource and collecting such a focussed cluster of motivated people.

[Kevin Sharpe]

1. what is the calculation to determine the battery and motor required for a specific range if the weight of the vehicle did increase?

If you use a Tesla Model X Long Range as a benchmark you won't go far wrong;

Battery Capacity: 100 kWh
Electric Range (WLTP): 500 km
Curb Weight: 2500 kg
Coefficient of Drag: 0.25

You can ignore the motors impact on range. Just select one thats already delivering your required performance so you're not the developers guinea pig. You'll also want to think seriously about whether you use a closed or open source solution (here).

2. presumably there are more parts needed to actually bolt all this gear together - are they all available on the openinverter.org Shop?

No single source exists for the full kit of parts today. We hope to change that with the LEXI project (here) and several people from the New Electric course are working on a standardised kit of parts.