De ICEChevy Volt Battery PackWarp 9 InstalledAdapter Plate and Shaft CouplerRear batteriesAll cleaned updash
OwnerAlan Nasar
LocationEatontown, New Jersey United States map
Vehicle1971 Volkswagen Karmann Ghia Convertible
DC 180 volt system
using Chevy Volt battery pack broken into 4
sections. 2 batteries in the rear next to the
motor, 1 behind the rear seat and 1 in the
front trunk on top of the horn. No BMS.
MotorNetgain Warp 9 Series Wound DC
Series wound DC motor with advanced timing.
170 volts max.
DrivetrainStock 4 speed manual transaxle with reverse.
Used adapter plate and shaft coupler from
Wilderness EV which required additional
machining to install properly. No clutch.
ControllerEvnetics Soliton JR
Max Current 600 Amps Continuous
Rated Power: 180 KW
Input Voltage 8-342 Volts
I added liquid cooling
Batteries96, 3.70 Volt, Lithium-Ion
Complete 2013 Chevy volt Lithium Ion
battery pack. 96 modules total, 3.7 volts
& 45 ah each. 48 modules in series x 2 for
battery voltage of 178 volts. 16.5 kWh.
Configured as 4 separate 24 module blocks
80 lbs each block.
System Voltage180 Volts
ChargerElcon PFC 2000+
Runs on 120 or 240 volts
DC/DC ConverterElcon TDC
Max Input Voltage Range: 108 - 216 volts DC
Output Current Range: 0-30 Amps at 12 volts
InstrumentationAmmeter voltmeter with connection to
Top Speed90 MPH (144 KPH)
Still had room to go in 4th.
Should be good for about 100 mph. Stock top
speed is 86 mph.
Acceleration0-60 9.8 sec 8/29, 600 amps, 3rd gear.
0-60 run 13 sec on 8/12, controller
limited to
amps. Started in 2nd, shifted to 3rd.
Stock 0-60 is 21 sec.
Range60 Miles (96 Kilometers)
approximate, Have gone 40 miles wth voltage
starting at 197 dropping to 179. 55 miles
starting 197 dropping to 162.
Watt Hours/Mile260 Wh/Mile
Round trip including highways and city
EV Miles
Start:82,720 Miles (133,096 Kilometers)
Current:84,748 Miles (136,359 Kilometers)
Total:2,028 Miles (3,263 Kilometers)
    As of 6/21/2020
Seating Capacity4 adults
Curb Weight2,000 Pounds (909 Kilograms)
Should be about 200 lbs over stock
TiresNankang CX668 165/80 R15
Additional FeaturesGigavac P105 Mini-Tactor Contactor Relay -
1200 VoltsFerraz A30QS500-4H - Ferraz Shawmut
500A 300VDC Fuse w/ Holder
Gigavac Maintenance Switch HBD41AA 1000V 400A
Continuous Hermetically Sealed (Main Switch)
WarP-Drive Hall-Effect Cable-Pull Throttle
WarP Motor Speed Sensor Kit
First drive 7/24/16. Drives well.
7/28/16 Couldn't get the Synkromotive
controller to charge the
batteries so I ordered an ElCon PFC 2000+.
Ordered another fuse to
protect the front battery from short
The rear end is a little low so I
ordered coil shocks for the rear.
Coil shocks installed 8/10, work great.
is at a normal height.
Elcon charger works nicely.
Got a tach and mounted in dash, disabled
controller RPM sensor.
Installed Custom Autosound replacement
stereo & speakers with subwoofer. Sounds
9/13/16 Had some electrical problems,
fuses, controller shutting down
intermittently. Traced to a short in the
reverse switch. Back in business.
11/11/16 Custom made 2x1 steel and
attached to floor pan from underneath to
stiffen chassis. Replaced front brakes
including disks, pads, and lines. Bought
rear brakes didn't install yet.
8/15/18 Installed high frequency battery
balancers and installed Elcon PFC 2500 up
front. Got new top, upholstry, paint.
Ditched Xantrex and got VDO voltmeter and
tachometer instead. Placed panel voltmeter
and ammeter hidden under dash. Car runs
great. Back window is original glass, leaks.
10/4/19 going strong. Glass broke changed to polycarbonate. 4/2020
Installed Soliton JR controller. Car runs well.6/2020 installed on
board 12 volt battery charger and switch

code by jerry