| Owner | Mikko Turunen | ||||||
|---|---|---|---|---|---|---|---|
| Location | Central Finland Finland map | ||||||
| Web/Email | WebPage | ||||||
| Vehicle | 1989 Volkswagen Golf mk II Cheap and common, fits my bill nicely. Got it very soon after it got inspected as an ICE vehicle for a last time. New front shocks and rear brake lines at that time. | ||||||
| Motor | Kostov 9 inch 220V Series Wound DC Prototype version. Only had been run in test bench. Fields configurable for series/paraller operation. This one runs in paraller mode only (for more RPM at this voltage level) | ||||||
| Drivetrain | 4-slot (+reverse) manual gearbox. Originally 1.6 engine with over 300 000 kms (~ 187k miles). Ran fine. Gearbox support cushions were gone. | ||||||
| Controller | Open ReVolt rev. 2C (144V/500A) max. 144V/500A, passive air cooling. Lots of configurable parameters and serial data communication for logging & setting parameters. HE throttle modification done later. | ||||||
| Batteries | 45 Thunder Sky LFP90Ah, 3.20 Volt, Lithium Iron Phosphate Cells were in really bad shape when I got them. All of them read less than 0.1V per cell, but 23 recovered simply by charging. Still I abandoned one of those 23 recovered and added 8 new cells to get 30 cell configuration. Later I ordered even more to get 144V system. | ||||||
| System Voltage | 144 Volts | ||||||
| Charger | TC Charger 1,5kW PFC Same as ElCon but bought directly from Chinese manufacturer. | ||||||
| Heater | 4x 1500W ceramic heater elements (rated 1500W at 120V). Serious and instant heat even if it is -22F (-30C) outside. 2x SSR relays to control full/half heat power. | ||||||
| DC/DC Converter | TC Charger 400W, isolated From same company as charger. Input isolated from output, 13,8V floating charge voltage. | ||||||
| Instrumentation | Stock speedometer, aftermarket tacho and Cougar LCD (motor & battery amps, pack & accessory voltage, SOC, different temperatures). | ||||||
| Top Speed | 77 MPH (123 KPH) It just didn't go faster on flat road. 400 motor amps and 270 battery amps limits were used at that the time. | ||||||
| Acceleration | 96V figures: 0-30 mph (50 kph) ~6 sec. 0-50 mph (80 kph) ~16 sec. 50-60 mph (100 kph) some patience | ||||||
| Range | 45 Miles (72 Kilometers) Mixed driving range. DOD >90%. | ||||||
| Watt Hours/Mile | 125 Wh/Mile 115A/96V at 80 kph (50 mph) 175A/90V at 100 kph (63 mph) ~80A/140V at 80 kph ~120A/135V at 100 kph | ||||||
| EV Miles |
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| Seating Capacity | 5 adults | ||||||
| Curb Weight | 2,100 Pounds (954 Kilograms) 96V system: Gained 75 kg after everything done (about +165 lbs). Still has load capacity of 450 kgs (990 lbs). 144V system: added 50kg of batteries and some more kgs of steel framing. Still enough load capacity for 4 normal sized adults. | ||||||
| Tires | Nokian Hakka Green (175/65/13) on some old aluminium rims. | ||||||
| Conversion Time | About one full year from buying donor car to passing inspection. All the work done in about 30 weekends. Didn't have much time in hand. | ||||||
| Conversion Cost | About 7500e (9500$). Was ~8300$ before voltage upgrade. Including everything. Almost every nut and bolt too. | ||||||
| Additional Features | All the interior lights are replaced with leds including dashboard/gauge illumination. Footwell lighting also added for both sides. | ||||||
| Road legal conversion. Passed inspection on 9th march 2011. Been driving daily since. Boring city driving video available at WebPage /> another: WebPage /> Lots of pictures at: WebPage /> 1467415551105?banner=pwa ----- updates: June 20th, 2011: updated Wh/mile figures after installing Cougar LCD instrumentation mainly for pack voltage display. It also drives stock fuel gauge which displays SOC. Other info included in LCD: motor/battery/controller temperatures, motor/battery amps, accessory voltage, SOC in percentage, kilometers-to-empty. Planning installing batteries in different order to gain more cargo space. August 8th, 2011: added a video link and two pictures. Car is getting front battery rack as it feels a bit heavy at back. Front box will house 20 cells and new box at the back will house another 25 cells. Yes, voltage is going up too. New charger and proper fuses are on order. More miniBMS boards and new wiring are also needed (orange & double insulated to pass inspection for voltages over 120V). September 7th, 2012: voltage upgrade done. Actually it was done during January and inspection passed right at the first try. Major heater output improvement. 96V DC/DC blew the first time it received 144V, bought same kind of unit but made for 144V. Replaced aux battery with 4x 90Ah old TS cells. Reduced max motor amps to 400 due excessive clutch slip at 500A. Replaced worn CV joints. Added aftermarket tachometer and led parking lights to the front. Bought new LRR tires but didn't notice any improvement in efficiency. Tested top speed capability and got 77 mph. It doesn't go any faster at these settings. 2nd gear takes me to 37 mph (60 km/h), after that 3rd gear works up to 60mph. Torque stays up until 4000-5000rpm. I like it. I'd like to add even more voltage to get everything out of this motor (220V+) but then again I should upgrade every power component. spring 2015: Framing under the car got too rusty and I got tired of sheet metal welding. Ripped all the electronics away and called local scrapyard to have them pick up the rotten body. Most of the batteries went into a riding lawnmower conversion and rest have been used as trolling motor battery and whatever I could imagine. Very handy and powerful batteries. Some old cells gave up during the winter. I've been thinking mk3 conversion since. I'll definitely do it one day. | |||||||
1989 Volkswagen Golf Mk II
“golfwagen”
Last Updated 06-06-2016
Copyright © 1997-2024 by Mike Chancey