LocationGothenburg, Vastergotland and Bohuslan Sweden map
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Vehicle1991 Volkswagen Golf II
VW factory built.
Motor ABB GN21 Separately Excited DC
Drivetrain5 speed and reverse gearbox clutchless.
Normaly uses only 2:nd and reverse.
ControllerOpen ReVolt 2pc modified for SepEx motor
Originally was a ABB SepEx controller but
now repleced by 2 modified Open ReVolt
BatteriesHeadway 40152 15Ah, 3.20 Volt, Lithium Iron Phosphate
Cells configured 36S6P
System Voltage115 Volts
ChargerElcon 2500W HF/PFC LiFePO4 Charger
HeaterDirect air PTC-heaters (2pc, 1500W each)
replaced stock diesel powered water heater.
DC/DC ConverterKelly HWZ
InstrumentationStock + BMS from JH Elektronisk Design.
Top Speed60 MPH (96 KPH)
Range40 Miles (64 Kilometers)
Measured in dry weather and decent
temperature (15 deg celcius) with 80% DOD.
Seating Capacity2 adults.
Curb Weight2,500 Pounds (1,136 Kilograms)
Target weight with LiFe batteries.
Conversion TimeI took me about 4-5 month from purchase to
passed car inspection with new batteries.
Conversion CostApprox. 70000sek (10600usd)
Working on replacing stock Lead-Acid battery pack with
LiFePO4. Done!

March 2012: Passed car inspection.

Feb 2013: Motor controller replaced by Kelly KDZ12403 after
the originally one broke.

March 2013: Motor controller is not doing what I expected. I
will try to replace it with 2pc Open ReVolt controllers, one
for armature current and one for field current. The one for
field current modified for small currents and to use motor
speed input instead of throttle.

Jan 2014: The Open ReVolt controllers are in. Passed car
inspection again after over a year in the garage. The car is
usable but not using field weakening yet. Needs some more
modification of the controller firmware and motor RPM input
for this.

Jan 2014: Now the field weakening works which is great. No
more gear shifting while driving. Now remains to sort
electric reverse and then I am all set with the controller.

March 2014: SOLD!

code by jerry