Main Controller BoardInstrument ClusterRear Battery CageRear Battery BoxRear Battery BoxFront Battery BoxUnderside of VanLooking Pretty With New PaintPassenger Compartment
OwnerFred Weber
LocationSan Jose, California US map
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Vehicle1978 Volkswagen Type II Van
MotorNetgain Warp 9 Series Wound DC
ControllerCurtis 1231
Batteries24 US Battery 125XC, 6.00 Volt, Lead-Acid, Flooded
System Voltage144 Volts
Charger PFC 1500
HeaterNone
InstrumentationAMP (0 to 500)
SOC (state of charge)
12V aux
Top Speed60 MPH (96 KPH)
Easy enough to get 60MPH on flat highway. About 250A to sustain that.
Acceleration0-30 9.4
0-40 15.6
0-50 29.6
0-60 43.2
Range55 Miles (88 Kilometers)
With a single charge we get a solid 50+ miles. At about 55 miles we see a noticable drop in performance and can't get above 25MPH.
EV Miles
Start:69,216 Miles (111,368 Kilometers)
Current:70,523 Miles (113,471 Kilometers)
Total:1,307 Miles (2,102 Kilometers)
 
    As of 11/6/2009
Seating Capacity5 seats, room for 8.
Original front seats and rear bench. Can also seat 3 on front battery box.
Have had 6 people (3 adult, 3 child, 1000#s in it so far)
Curb Weight4,300 Pounds (1,954 Kilograms)
After Conversion: 4300, Front 1850, Rear 2430
Before conversion: 2600, Front 1060, Rear 1510
GVW Specs: 4961, Front 2227, Rear 2800
TiresYokahama Y356 185R14/D1
Currently inflated to 55psi
Conversion TimeMy log shows:
46 hours of restoration of donor
22 hours of design
80 hours of conversion
I didn't keep perfect track. I guess it is more like
100 hours of purchase/restoration
40 hours of design
80 hours conversion
35 of the total hours was from my wife, kids, brother in law and Mike Brown at ElectroAutomotive
Conversion CostDonor Purchase and Restoration - $10,900 including bodywork, paint and glass
Conversion - $13400
Tools I didn't have - $500
Additional FeaturesOverall I love the conversion and we are already using it as a daily driver instead of our Honda Odyssey. A few minor issues/observations:
- A bit hard to get a smooth start. Best result is third gear without clutch. Get chatter in first, second and third if I use clutch. Not sure yet if it is me, a problem in my setup or basic to the design. After a month of driving we are much smoother.
- Brake vacuum pump is louder than I would like and kicks in with every stop
- Controller whines a bit at low current
- Motor whines a bit
I have design files for battery boxes, cages and wiring and am happy to share those with anyone interested.

Bought Conversion Kit from Mike Brown at www.electroauto.com
Battery cages welded by Robeck’s Welding in San Jose

Conversion Timeline:
2/28/09: Bought Van
4/13/09: Rust stopped, basic restoration in good shape
4/25/09: Removed engine
5/29/09: Installed first EV components - vacuum pump
6/15/09: Lights and other electrical system in good shape
6/23/09: Most of EV Kit has arrived. Design done. Order battery boxes and cages
7/09/09: Built main control board
7/27/09: Picked up battery boxes. Begin 3 day marathon to complete conversion
7/29/09: It's alive. On the road and driving
9/6/09: 70,000 miles on odometer. 800 miles in first 5 weeks of driving. All is well.
9/19/09: Took in to get exterior painted. Will be out of commission for 3 weeks
11/4/09: Paint job is finished. It looks great.

code by jerry