Aussie COUGAR Controller
OwnerIan Bartie
LocationWauchope, New South Wales Australia map
Web/EmailWebPage email image
Vehicle2001 Volkswagen Polo
1.4 DOHC, 5 speed manual, 5 door
MotorNetgain Impulse 9 Series Wound DC
DrivetrainStock transmission with clutchless coupling.
Use 2nd & 3rd gear.
Clutch going back in.
ControllerOpen ReVolt COUGAR Open Source Aussie version
144V 500A programmable open source controller that I built myself.
Batteries45 CALB/Skyenergy CALB 130Ah, 3.20 Volt, Lithium Iron Phosphate
System Voltage144 Volts
ChargerZivan NG3
Fitted with a custom AZ Lithium curve from the factory.
Heater120V 1500 watt ceramic heater running off 144V. Switched with 2 x 220V DC relays.
The original 240V one was useless so I bought a 120V one from the US.
DC/DC ConverterIota DLS-55
Modified to work on DC only.
Current inrush limiters have been fitted.
InstrumentationAll standard including tacho. The fuel gauge show the SOC & the temp gauge shows the battery amps.
There is also a custom LCD display that shows pack volts, aux volts, motor amps, battery amps, motor, controller & battery temps, charging time & charging current.
Top Speed75 MPH (120 KPH)
The car does not go much faster that anyway except down a hill.
AccelerationAcceleration is better than original especially if 2nd gear is used.
Range95 Miles (152 Kilometers)
150km is the maximum range driving gently with no high speed.
100km is kinder to the pack & usual daily use is around 30-70km.
EV Miles
Start:101,280 Miles (162,959 Kilometers)
Current:115,885 Miles (186,458 Kilometers)
Total:14,605 Miles (23,499 Kilometers)
Seating Capacity5 adults in a Polo - yeah right.
2 adults & 2 kids no problem.
Curb Weight2,375 Pounds (1,079 Kilograms)
This is the curb weight of the finished car.
It wound up being 40kg heavier than before. 20kg on the front & 20kg on the back.
TiresFalken 185/55 ZE912 silica polymer compound
Conversion Time12 months in the planning & aquiring all the parts.
6 months in the actual conversion. 100% done now.
Conversion CostA lot of time mostly!
Doing an electric car conversion properly & getting it right is a bit more involved than what I had envisioned.
The financial cost was spread over a year so I did not really notice it.
Additional FeaturesOriginal air conditioning is retained & is driven by the tailshaft of motor via a custom pulley.
Power steering is retained & the power assistance is provided by a Toyota late model MR2 EHPS unit.
A VBS pump kit supplies vacuum for the brake booster.
I did have Thomas pump but I scrapped it because it was too noisy & too slow.
Dual Kilavac contactors, dual traction pack fuses & an inertia cutoff switch for added safety.
The conversion is totally finished.
I drive the car every day for the usual school run & shopping.

code by jerry