Adapter building – EV conversion
Like others I am disassembling the clutch disk, so I can have something to fit the splined shaft of the transmission.
Here is the before.

Electric car adapter/coupler building
Just grind off a few pins and it will pop apart.

Clutch disk apart
I have a second clutch disk as a back-up. It is slightly different, but this one seemed to fit the shaft very good. I will update as I get more parts for the adapter.
Get a working vehicle for an EV conversion.
My original plan was to purchase a working, running VW Beetle to convert to electric. Saw this project and thought perfect.
Save some time and get a working vehicle so you know what you have!
Re-indexing “Lowering” VW Beetle
The previous owner had raised the rear of the beetle for 31″ tires. At first I thought maybe there was something rusted together, because it was so stiff. Now, I know that they just didn’t know what they were doing. There are tons of VW Beetle service manuals that tell you how to lower/raise the rear end. I found 4 videos on YouTube that provided me with enough info to get the job done and only took about an hour (not including the time to remove rusted/broken bolts!).
Here is the video link:

Trying to remove broken, rusted bolts
Configuring the Alltrax AXE 7245
So, I’ve had this big paper weight on my desk for about a month now. I was hoping that after I cleaned out the basement one of the “computer boxes o’ junk,” that there would be a serial to USB (9-pin RS 232 to USB) so I could play around with the Alltrax AXE 7245 settings, but nothing was found. I have one on order and hope to receive it soon!
The Controller Pro software looks pretty basic and extremely user-friendly. But, the settings will be more than enough for me. You can adjust the General settings, Throttle response and even record the performance. The Monitor option sounds cool as it will be perfect for my wife’s netbook.
Here are the options available to the AXE (also has DCX optioins listed) controllers.
|
Once my new cable arrives I will screen capture some of the configuration pages.
Save energy – Ride a bike.
If you don’t like gas prices ride a bike. At least Rep. Patrick McHenry didn’t recommend walking, because that would be taking things a bit too far.
The new old VW fenders for the Beetle
My project didn’t come with rear fenders and I think I have spent the last 3 months trying to find some locally. I couldn’t even find crappy ones. But all that changed yesterday as a guy going to school at Iowa State had some left over parts from a build. But for $20.00 and I got some used, good condition rear fenders for the VW bug. So, I immediately got them home and cut them up into bits. Hindsight, I might have trimmed them a bit short, but I wanted to clear a nasty dent on one of them… and I didn’t want them to extend too far back from where the body had been cut. I’m sure the local police will let me know if I don’t meet the street legal requirements.
-
Alltrax AXE 7245 Controller
Got the controller for the Bug today. It is an Alltrax AXE 7245 controller. 24-72 Volts, 450 amps. Just need to get this thing DONE. Parts are coming in, excitement is brewing. Photo… I need to find the SD card for the camera (think the kids have it in the Wii). If you don’t know about Alltrax you can find their website here.
If you want to know prices or where to purchase… I got mine here from EV Drives.
Will update with photos. It looks snazzy!

Alltrax AXE 7245 Controller - also pictured is the Kilovac contacter, pre-charge resistor, diode and fuse.
Buying locally
I give every effort to purchase locally. We are a small town of about 1500 people (census 2000). And we are about an hour from what I consider the “big city.” So, it makes sense to buy locally vs drive time and gas just to save a buck.
But… I am already boycotting one of the two auto parts stores in town, mainly due to the owners attitude after I wanted to return a fan belt for a Jeep I had. My Jeep had an aftermarket AC unit so the stock belt didn’t fit. So I returned it. He gave me grief because I waited a day before returning it. Then harped even more after he realized I paid with my debit card (I understand he probably got charged a fee, but from my knowledge he should get it returned from the bank). So, there’s one business I refuse to do business with. But still I try.
So, anyway I got to the local farm store (which is part of a larger chain). *cough*Orscheln*cough* And I needed to get some bolts for the rear swing arm of the Bug. So I grabbed some lock washers, flat washers and nuts on the bolts, and threw 6 sets of them in the little nuts/bolts plastic bag (2 washers and a nut on each bolt). At checkout the lady rudely told me that the lock washers are not the same price and that “you almost got away with it” because I had washers and nut on the bolts. Even though the nearest sign to the lock washers was $1.79. So, as I was leaving the difference in price if she would have charged them all the same was 9 cents.
How does that ballgame heckler chant go… oh yeah, Nuts and bolts, we got screwed!
Blog updates and archives
Since this blog is about building the electric VW Beetle. I am currently (finally) at the point where I am purchasing and assembling the electric car components. Since A TON of work has been done just to get the Beetle road worthy, I will be adding posts, photos, info that has already happened (older posts are mostly going to be automotive maintenance/repair – I will try to put them in a separate category). Since the JPEG images from my digital camera have the dates, it should be a fairly easy process to insert the posts where they go.
2/0 Welding cable for the EV battery pack
There are plenty of EV sites on the web and all seem to offer different advice on the size of cable needed for the battery pack. I have read some say 1/0 welding cable is fine, while others recommend up to 4/0 welding cable. (Welding cable seems to be the best choice since it very flexible and ideal for routing through the car). I am going to assume the 4/0 is for the higher volt/amp packs… i.e. 144 volts or greater. Since our little electric vehicle is planned at only 48 volts I would think that the 1/0 welding cable would do just fine. But since I found a great deal on a 50 foot, 2/0 welding cable (free shipping) and to top it off it is made in the USA. The 2/0 cable also allows me to change the battery pack voltage later if so desired without the need to upgrade all the cable.
Here is where I purchased my welding cable :: Harris Welding Supply.

50 foot of 2/0 welding cable