Voltswagon 2008 Beetle Electric Conversion all done!

2008 Beetle Electric conversion (for Sale 16k CDN) .. on to the next project...
Thanks to John and the guys at Thunderstruck Motors www.thunderstr... they sell great products!
Thanks to Don and Brian for the help in machining of the transmission input shaft and hub and thank you to Kyle for your help with the programming on the nasty ESC Controller for the power steering!

[@yavindaweerasekaraarachchi5439]

Even though I know nothing about vehicles, this conversion made me a lot happier. Glad I found you out randomly. Really need something like this in our country considering the fuel prices.

[@rodn6766]

Thank you!

[@DruzCruise]

Extremely clean conversion.

[@rodn6766]

thanks!

[@rodn6766]

If anyone is interested in tackling one of these will be glad to share any build information you need

[@michaelbarden6987]

I am, I just pulled the engine out of my beetle

[@rodn6766]

@@michaelbarden6987 hey Michael what year? Automatic or standard?

[@michaelbarden6987]

@@rodn6766 standard, I didn't want to use a Lovejoy connection, so I cut the flywheel connector plate free of the camshaft, I'm going to have a machine shop drill it out to attach to the motor. Debating with myself if I should try to put an Audi tt quattro drivetrain in it.

[@michaelbarden6987]

@@rodn6766 98

[@rodn6766]

@@michaelbarden6987 interesting, so you cut the flange off the crankshaft and are going to use it for a motor coupler? good plan, not sure what motor you are using but would make sure the one your using will be ok with the bearing end load from the clutch (if your going to be using it) what are you using for batteries/ bms / motor controller?

[@natashaprime3484]

So the original transmission was automatic? Awesome! I am thinking about doing something similar. Not a lot of videos of people doing this on automatics. I’d be interested to learn more

[@rodn6766]

Here are some videos on how the transmission was modified. The clutch packs , pump, planetary and the valve body were all removed m.kzbin.info/door/K86lfdsJG1B1WQJgkxkp0w

[@PetawattsAutoMarineRVLtd]

Very nice and neat build, congrats!

[@JamieJones1985]

Cool to see another converted New Beetle. Mines got about 27kWh pack, chademo, 3.3kw ac charger. its a cool car to convert.

[@rodn6766]

You have pics or video of your build? Would like to see it

[@mfhthenycflyguy7085]

Awesome conversion! I want to do same!

[@rodn6766]

Yea real happy with Herbie, just wish i would have documented the build a bit better! Next time!

[@mfhthenycflyguy7085]

@@rodn6766 Next one, thanks for sharing the finished product? Did you use a blueprint, kit, or have a good EV reference for the build?

[@rodn6766]

@MFH the NYC Fly Guy Nope started by pulling the motor and transmission. I did bit of research on the motor before I bought the VW (weight torque gear ratio tire size etc) If you decide to do it, I could talk you through the process

[@mfhthenycflyguy7085]

@@rodn6766 thanks @rod n; I’ll let you know if it comes to fruition! Enjoy your EV bug!

[@snailer06]

Power "Stearing". That must be the Canadian spelling? Great work Rod!

[@rodn6766]

Lol autocorrect

[@viteliohernandez]

Awesome, I'd love to do something like this on an older rabbit

[@EliteSim27]

Awesome!

[@davidhope5713]

This is my dream 🚗

[@rodn6766]

Well anything I can help you with say the word Dave!👍

[@CountryRoadCycles]

This is such a nice conversion. How where you able to figure out the Can-bus stuff? I have access to an A5 with a blown motor that I'm thinking of converting, but I'm worried I would never get the electronics straight. Any thoughts would be appreciated. Thanks!

[@rodn6766]

Hey Steve I messed around with the ecm for a few weeks removing DTCs .. after the 20th time in and out with the ECM I tried it without it completely! And it's 100% fine. I left the bcm/tcm/abs etc and all is happy. Had to reconnect the speed sensor in the transmission after I removed the valve body/solenoids etc. If you decide to go for it happy to help. The most challenging time consuming part I thing was wiring and programming the BCM but ext one will be a piece of cake!

[@blackterminal]

This is really good. Second time ive watched your video. How did you get on with the abs and airbags. Do the still see the car as moving and function as required? How did you get the engine warning lights to go away and if you had ignored them and just drove with the panel lit up with "faults" would it have mattered apart from being slightly annoying i mean. :) . Theres some beautiful modern cars that simply have unreliable petrol engines that would be good to get rid off like many BMWS for example but im not sure if it would be ok to just drive with the screens lit up with "faults. Ie would the abs and bags still work.

[@rodn6766]

The airbags and abs work fine (didn't disturb any of them) the ECM took quite by removing the DTCs one at a time (there was lots) but everything works like it should :)

[@thefirstdutchguy]

do you have any form of regen? I'd be very interested in the wiring diagrams!

[@rodn6766]

Yes it does regen .. using the hyper9 setup from thunderstruck-ev.com (and their MCU BMS /charger/ DC/DC converter The schematics for everything is there fir the motor/controller etc

[@Good-Enuff-Garage]

very clean build, I know I should watch more videos but I will ask anyway, so no gear reduction in the gear box at all ?

[@rodn6766]

Thank you .. Just the crown and pinion I forget exactly what the ratio was .. 3.41:1 or something like that

[@rodn6766]

youtube.com/@rodn6766?feature=shared there is a few videos on the internals Thanks

[@SoLA489]

How come the emergency flashers and not on the dashboard ?

[@abrahammonteropacheco7557]

Now please Dodge Challenger 2010 Tesla swap EV electric thank you very much

[@rodn6766]

That would be a fun project!

[@JaimeBurciaga]

Are you familiar with the last 2019 New Beetle version from Mexico? Do you think this conversion will work on them? Saludos (Best regards)

[@rodn6766]

Hey Jamie, sorry have never seen one of those

[@azmiaminibrahim]

interesting conversion, afew question, the auto transmission, what exactly you removed and how you control car gear change?

[@rodn6766]

It's direct drive, removed the pump, clutches, planetary. Just used the crown and pinion pretty much. There are some other videos on my channel that shows how I did the conversion

[@ThatTechGuy123]

I'm looking at buying a VW beetle to convert for my wife as a daily driver. How much did all this cost and did you have to do any fabrication?

[@rodn6766]

Probably 10-12k , 6 months of work and yes everything with the conversion was 100% fabricated except for the actual motor/controller/bms controller/charger

[@ThatTechGuy123]

@@rodn6766 if only someone would sell a conversion kit for this card that just bolts in place of the original parts

[@rodn6766]

@ThatTechGuy123 yea looking back I really should have done a better job of documentation and made templates... next time for sure. Yes I agree a kit would sell

[@azmiaminibrahim]

Which conversion kit you adopt? How about the AC compressor. How you convert to electric?

[@rodn6766]

I haven't bothered with the air conditioning yet was more concerned about heating it. As far as a conversion kit, it was 100% fabricated by myself. If you look at some of the other videos it shows how I converted the automatic transmission to a direct drive. The adapter plate was made from 1/2" aluminum plate.

[@christiantheimprovguy1769]

What would I want to budget for a project like this?

[@rodn6766]

I have about 12k cdn plus the cost of the car into it... and about 6 months of figuring it out

[@cesgonso]

How do you manage the SOC on the old gasoline gauge? very nice

[@rodn6766]

The thunderstruck BMS has a pwm output you can configure to give battery voltage with 3 or 4 offsets and setpoints .. it took a day or 2 to fine tune it but a capacitor on the pwm out line and tied it to the fuel gauge sensor line.. 👍

[@cesgonso]

@@rodn6766 thanks Rod, we're working a 1999 new beetle in Costa Rica, definitely would try to get ours working the same way

[@rodn6766]

@@cesgonso awesome !! Automatic or standard?

[@cesgonso]

@@rodn6766 standard transmission, with clutch, 36kW motor, with 20kWh battery pack

[@rodn6766]

@cesgonso that will be very nice please do lots of videos and make templates of everything you do.. wish I would of. Please keep me updated if I can be any help with anything give a shout!

[@michaelbarden6987]

actually I am. I just pulled the engine out of my beetle

[@Rottingboards]

How many miles are you seeing per charge?

[@rodn6766]

Lots of hills here so your always climbing Getting roughly 150-160 km to a charge. Plenty enough for a daily driver. Come home plug it in and on a slow charge (8 amp, not in a hurry) it's ready to go the next morning again