Trending Sources

Even In 2007, As VW Designed Dirty Diesels, It Said Electric Cars Were The Future

Green Car Reports

Many journalists tend to have pack-rat tendencies, but sorting out old press kits, files, and magazines can have unexpected rewards. So it was for auto writer John Rettie, who recently uncovered an interesting tidbit in an issue of Driver, the in-house magazine sent out by Volkswagen of America to owners of its cars.

Kits 12

Wiring and Rewiring - Getting Close!

Porsche 914 EV Conversion

Ugh, I'm dehydrated, exhausted and mad at this inanimate object. I must love doing this conversion. Here's the fusible link in the front battery box.

2007 11

Christmas Time!

Porsche 914 EV Conversion

On minor disappointment is that the cable supplied in the kit is #2 gauge cable. YeeHaw! The crate from Electro Automotive finally showed up.

Taking a Day off to see the EV Show

Porsche 914 EV Conversion

They run on 48 volts and the company sells them as a kit for about $3500. There were probably twenty electric vehicles at EV awareness day.

Routing Thick Cables

Porsche 914 EV Conversion

I've already added the 3-hole cap-plug provided in the kit. I didn't get any action shots, but here's the result. Today was a bit slow.

Forcing a Fit and Letting Sparks Fly

Porsche 914 EV Conversion

Also, the instructions for the DC kit may not apply to the AC kit. Here is the front battery box not fitting into the front rack. Cheer

There are many paths to the same goal.

Porsche 914 EV Conversion

Excerpt from Randy's e-mail: I've also started on the wiring kit. The slot was cut when I installed the Camp 914 shock kit.

Biting the Bullet

Porsche 914 EV Conversion

They provided an upgrade kit with lock washers and loctite to remedy the problem. Here's the back end of the transmission/motor.

Hauling Lead and Confusing Connections

Porsche 914 EV Conversion

A modification of the prior strap is basically what is suggested in the DC kit instructions. Tonight was an evening of heavy lifting. Goodnigh

Wiring up the Front Compartment

Porsche 914 EV Conversion

Here is the 9-in-1 wire for the AC kit pulled through the grommet between the passenger compartment and the fuel compartment. Onwards

Dear Customer.

Porsche 914 EV Conversion

I received a package from Azure Dynamics yesterday with a field upgrade to the bolts on the AC24 motor for the EV kit. Update: DOH!

Finishing the Serial Cable and Testing the Fuel Gauge

Porsche 914 EV Conversion

For some reason, I had an extra cap-plug left over from the kit, so I used it to protect the cable from the sharp metal edges.

Motor Cables and High Current Posts

Porsche 914 EV Conversion

Electro Auto forgot to include the post terminals for the most-positive and most-negative connections in the kit. It did not.

More Wiring and ACK, It Doesn't Fit!

Porsche 914 EV Conversion

Continuing with the wiring, here is the bundle of EV wires in the front luggage compartment, covered with the flexguard. IT DOESN'T FIT! ARGHH!

DC 2

Hacking the Regen System and Fixing Acceleration

Porsche 914 EV Conversion

In the original kit instructions, the regen relay turns on the brake lights when the AC controller is in regen mode. Mine was set to 136 volts.

Hacking Big Cables

Porsche 914 EV Conversion

As I mentioned before, I'm replacing the #2 gauge cable provided in the kit with a thicker 2/0 welding cable. Cheers

Hacked Serial Cable Details and Bad Relay

Porsche 914 EV Conversion

A few people asked me about how I hacked together a serial port since AC kit people will need this in order to configure the controller correctly.

Battery Equalizer Schematics Rev 1.0

Porsche 914 EV Conversion

I'll have to modify the circuit with a voltage doubler in the final stage to work with 8-volt golf-cart batteries for the 914 EV kit.

The Suspension is Here!

Porsche 914 EV Conversion

The real gamble is how fast the rest of the kit shows up. I received the suspension parts from ElectroAuto today. I'll check tomorrow

Getting the Tachometer and Lights Working

Porsche 914 EV Conversion

The original kit doesn't use the red light and the green light is simply grounded. got a pulse train corresponding to the RPM of the motor.

Fun with Rivnuts

Porsche 914 EV Conversion

Electro Auto shipped their first AC wiring harness to the first AC kit customer and it arrived today. Here's the Rivnut Gun.

Getting the EV Back to the Shop and Fixing Electrical Stuff

Porsche 914 EV Conversion

in the kit instructions), through a bolt connecting the large red wires, and then back to the ignition switch. This eliminated the 1.5

Let My People Convert! - The A123 Challenge

Plugs and Cars

Les Goldman wants you to convert (your hybrid.) Easy as 123. So he proposed at the California Air Resources Board ZEV workshop on Tuesday. Look it up.)

We are Green for 12V Electrical!

Porsche 914 EV Conversion

The dangling white and green wire go to the ammeter shunt and the dangling black wire I think is not used in the AC kit. Whew! engine.

DC 2

Spaghetti Wiring

Porsche 914 EV Conversion

Randy, another 914 EV AC kit customer is going to send me a few sketches so I can move things around, if necessary. I think that's it for today.

Motor/Transmission Attached!

Porsche 914 EV Conversion

Well, today was quite productive. Here's me torquing down the flywheel bolts again (80 foot-pounts!)

Debugging, Debugging, Debugging.

Porsche 914 EV Conversion

Okay, things don't seem to be working too well. We have three issues: 1. The controller simply cuts out at high acceleration (bad) 2. sigh).

Busy Day - Time to get your WooGah On

Porsche 914 EV Conversion

Note: The AC kit instructions don't say what to install the charger tray with. Whoosh! Here is the board that the charger tray mounts to.

Closing up more loose ends.

Porsche 914 EV Conversion

I'm still waiting on the battery racks/boxes from ElectroAuto, so I took care of a bunch of little things that have been neglected so far.

Starting the Wiring

Porsche 914 EV Conversion

The fifth wire called for in the AC kit instructions is supposed to be black with a yellow stripe for the rear brake lights.

Wiring up the Controller Harness

Porsche 914 EV Conversion

Today, I installed the last kit piece that I have from Electro Automotive: the motor controller wiring harness.

Still waiting for the Transmission

Porsche 914 EV Conversion

On a more positive note, Ross Cunniff got his 914 AC kit running recently and Bob has been making progress on his BMW 325i performance EV (see links at right). In the meantime, I'm helping other folks using the AC kits with the Azure Dynamics controller get their systems working. Still haven't heard from him. I'll try again tomorrow.

Plug-in Hybrid Bills in Congress Scare Auto Makers

Plugs and Cars

Calcars continues to work with the Electric Auto Association members to bring a do-it-yourself kit to hybrid owners with moxie. The Senate bill is known as the FREEDOM Act ("Fuel Reduction using Electrons to End Dependence On the Mideast Act of 2007"); the House bill the more prosaic "Plug-in Hybrid Opportunity Act of 2007."

EV Toolbox

Porsche 914 EV Conversion

pre-made 24" battery cable with lugs (from NAPA) #2 philips/standard screwdrivers pliers small utility knife to cut insulation small 12V SLA battery to bootstrap the system if 12V battery dies Again, what would you add/subtract/modify in this kit? I came up with the following items.

Talking with Mike at ElectroAuto

Porsche 914 EV Conversion

Apparently I'm the only person with an operational AC kit currently, although several other people are hot on the trail to finishing theirs. Mike doesn't have an AC kit 914 back at the ranch. I just got off the phone with Mike at Electro Automotive. We chatted about the blown CCPower DC-DC converter and the engine vibrations.

More Delays

Porsche 914 EV Conversion

Over the past few weeks I've been trying to contact the folks at Electro Automotive to get the status of the EV 914 kit. They finally responded last night and apparently they're completely buried under the demand for EV conversion kits. He got one of the earlier DC motor kits for the 914 from Electro Automotive.

An E-mail from Azure Dynamics about the DMOC445

Porsche 914 EV Conversion

I recently sent off an e-mail to Azure Dynamics, the maker of the DMOC445 AC motor controller in the 914 kit. Tim -- Original Message - From: Beth Silverman To: Tim Kutscha Sent: Monday, September 17, 2007 10:26:05 AM Subject: RE: tapping into the encoder signals to drive the RPM gauge Hi Tim, sorry, I was out Thurs and Fri.

My 2007 Dream Project

Porsche 914 EV Conversion

Since I live in Portland, Oregon, I went to a meeting with the Oregon Electric Vehicle Association and found out about several companies that provided drop-in electric conversion kits for existing cars. I hope everyone had a great 2006 and I wish you all the best for 2007

NMG 2

Two Week Commuting Report

Porsche 914 EV Conversion

With the motor out, I'm going to look into RPM kits for electric cars that use spinning magnets on the flywheel with a magnetic sensor to generate a signal. Since I don't work Fridays, this is the end of my second week commuting to work fifteen miles each way. Two things have definitely made the car more fun to drive. doh!) Stay tuned

Measuring State-of-Charge on Lead Acid Batteries

Porsche 914 EV Conversion

The 914 AC kit uses 8V golf cart batteries and I'm wondering if different batteries like Hawkers or Optima Yellow-Top batteries would be better. Since I'm still waiting on parts from ElectroAuto, I decided to take the plunge and do some extensive research on Lead-Acid battery technology.