ICE Breaker - 1967 VW Splitscreen Bus with Tesla Drivetrain/Battery

[Kevin Sharpe]

Just a few photos of the "ICE Breaker" project with lots more details to follow... for historical posts please see my DIY Electric Car Forum thread (here)

[johu]

Clean Conversion² (as in clean code x no emission) haha.

I might have missed it in the historical thread but are you using that Type 2 DC fast charge port? Where did you get the socket from?

I consider using Type 2 instead of Chademo in the Touran because it seems to be more common in Germany.

[D@F]

I might have missed it in the historical thread but are you using that Type 2 DC fast charge port? Where did you get the socket from?

I consider using Type 2 instead of Chademo in the Touran because it seems to be more common in Germany.

yes same question for me and same consideration for my golf....

[Kevin Sharpe]

I might have missed it in the historical thread but are you using that Type 2 DC fast charge port?

Today we are using the Type 2 AC pins for 22kW three phase. Our long term goal is to use the Type 2 DC pins and I'm making some progress on finding a vendor for the HomePlug Green PHY that's required. Ideally I'd like to see the PHY added to Damien's Tesla charger board in a future release

Where did you get the socket from?

We purchased some from a vendor in China. I believe that Zero EV in the UK (here) will sell them in future, I'll ask Chris to comment here.

I consider using Type 2 instead of Chademo in the Touran because it seems to be more common in Germany.

Both Damien and I plan to use the Tesla CHAdeMO adaptor (see photo) which will allow our cars to charge from AC (single/three phase to 22kW), CCS DC, and CHAdeMO DC

[Kevin Sharpe]

loading 8 Tesla P100 modules (50kWh) into the 'belly' of the bus today

[tom91]

Now thats a tight space for those batteries, specially having seen it first hand.

Good thing you will be reusing the Tesla BMS thus not requiring alot of wires.

[Kevin Sharpe]

Now thats a tight space for those batteries, specially having seen it first hand.

Good thing you will be reusing the Tesla BMS thus not requiring alot of wires.

Yeah, it's cosy in the 'belly' battery box

[Kevin Sharpe]

Another 4 Tesla P100 modules (25kWh) in the rear of the bus

[Kevin Sharpe]

Amazing what you can test with a €50 Toyota Prius battery

[Kevin Sharpe]

I recently purchased a new BMW i3 covering cap for the CCS charge port connector that I have fitted on the bus. The part number is 61 13 9 343 122 and it cost €36 from a BMW dealer

BMW also sell the caps without the CCS DC part if you're just fitting a Type 1 ("J1772") or Type 2 ("mennekes") connector and need some extra weather proofing. I don't currently have the part number for those versions.

I'll get some photos taken when I get a moment but for now here are some library pictures.

[Kevin Sharpe]

Simple pleasures... an automatic light for the charge port

[johu]

Nice Was there an existing switch you could use or how do you trigger it?

[tom91]

Quick question:

Will it stay on once charging commences? And be an extra 12V drain, or you have some switching logic?

[Kevin Sharpe]

Nice Was there an existing switch you could use or how do you trigger it?

No switch in the bus so installed a proximity sensor to detect the fuel flap open/closed

[Kevin Sharpe]

Quick question:

Will it stay on once charging commences? And be an extra 12V drain, or you have some switching logic?

I'll build in some logic to turn it off once charging starts. I also have an RGB LED for charging status indication. Hopefully the Tesla CCS controller will take care of this for me

[Kevin Sharpe]

I decided to reuse the Tesla Model 3 charge port thermistors in my CCS connector. I haven't attached them directly to the DC power pins as per the Tesla connector but went for an easy option of using existing screws located in both the AC and DC pin area.

Hopefully they will give me a rough indication of the connector temperature during charging and also provide compatibility with the Tesla CCS controller (here)

[Kevin Sharpe]

We have some new toys... 1000A IVT-S 'shunts' (data here)

[tom91]

They are really nice, incooperated them into the SimpBMS already.

[JaniK]

Great project!

Could you help by sharing some details,

Between chassis rails on the belly, is it still stock width/chassis rails?
How about weight of the bus?
Consumption?

-58

[Kevin Sharpe]

Between chassis rails on the belly, is it still stock width/chassis rails?

No changes needed to the chassis rails. We didn't want to cut the floor of the bus and therefore allowed the belly box to protrude 25mm below the chassis rails to give us some extra height for battery modules. In reality this has not been a problem even though I've lowered the bus from stock ride height.

How about weight of the bus?

I'm currently plumbing the cooling system in the belly box. Once that's complete I'll reinstall the battery in the bus and put it on the scales.

Consumption?

No idea today. We're still driving with the Prius pack

[JaniK]

Thanks for the answers!

Still prius energy

Your project is huge inspiration to me.

[Kevin Sharpe]

Your project is huge inspiration to me.

Thanks, it will be at Fully Charged Live in May if you want to see it (and meet Damien and Johannes)

If I was starting today I would try and find an automotive engineer who could develop a high performance chassis that would accommodate the entire Model 3 pack and motor. Failing that I would use four of the 'short' Model 3 battery modules in a belly box. Unfortunately, both options would require extensive chassis modifications and make it difficult to get it approved for the road in Ireland.

[JaniK]

Thanks for the invite!

...
Unfortunately, both options would require extensive chassis modifications and make it difficult to get it approved for the road in Ireland.

GETTING A LITTLE OFF TOPIC, SORRY:

Same goes here in Finland, follow the rules if you want to legally drive on the road.. There are changes on the way for changing motor, currently only +20% power is allowed, new law would add power to weight option for low powered cars, for VW Type2 it would allow up to 12kg/kw motor to be changed and approved in normal MOT office. (So a 1200kg car could have max. 100kw, that maybe also the upper limit but the law is not complete yet)

- there is kind of individual car acceptance option, but that is a lot of paperwork, calculations, planning, applications and it is basicly ment for making a work vehicle, so you will be asked: Why you NEED this??

I also think starting today the model3 battery is propably worth it if it fits, I have no floor panels currently, so I think I will make "Wooden 1:1 Model 3 battery modules" (maybe others too) to play with and test fit -maybe continue on that with a new thread with some pictures..

-Jani

[Kevin Sharpe]

so much Tesla battery plumbing

[larsrengersen]

Cool! Using the P100 modules is a hot topic.
Do the colors imply you have a in/out (assuming cooling)?
Or does it imply you have a heating and a cooling sub circuit within the module?
How did Tesla use the modules?
I was expecting counter flow for better heat exchange.