Instrument PanelFront PackFleet
OwnerJarrod Botttinelli
Owner's Other EV1968 Volkswagen Beetle
LocationLos Lunas, New Mexico US map
Web/Email email image
Vehicle1974 Volkswagen Karmann Ghia
MotorNetgain Warp 11 Series Wound DC
DrivetrainStock transaxle, will upgrade to KCR performance
transmission with 3.44 R&P, welded 3rd and 4th
gears, super differential. Kennedy stage III
clutch, lightened EV specific aluminum flywheel
from EV West
ControllerZeva MC 1000 (1000 amp)
Very impressed with this controller. When
combined with the EVMS, programming and
monitoring many controller parameters is very
easy. Linked with CAN Bus interface. Much
thanks to Ian Hooper of ZEVA for extremely
good customer support.
Batteries45 Voltronix 180 Ah, 3.20 Volt, Lithium Iron Phosphate
24 behind seats, 21 under hood
System Voltage144 Volts
ChargerElcon PFC 1500
HeaterHomemade from heating element of a 1500W space
heater engaged by 400 amp contactor and 12 volt
270 cfm marine blower. Works very well.
DC/DC ConverterMeanwell SD-1000H-12
InstrumentationEVMS monitor, Speed Hut Speedo and Tach, No BMS,
individual voltage meters on each cell,
temperature gauges for both battery packs and
Top Speed95 MPH (152 KPH)
Will be faster after changing ring & pinion
ratio. At this rpm (4000+), reduced net voltage from
back EMF is limiting motor current to around 300
Acceleration0-60 in 6.1 seconds entirely in 4th gear.
Even with the stage III Kennedy clutch and non
slip ceramic disc, the clutch still slips when
I floor it in 4th, so it is not performing to full
potential. If I start in a lower gear, I need
to shift to 4th at some point due to the more
severe back EMF with the Warp 11. I can't
shift quick enough to break 6 seconds. I
expect this to improve after replacing the
tranny with a 3.44 r&p and doing it in 3rd
gear. I expect it to beat my bug which has a
Warp 9 yet does 0-60 in 5.3 seconds! It will
also be faster if I can prevent the clutch
from slipping. Considering a stage IV pressure
plate. Also, I haven't really dropped the
hammer yet because it will probably destroy
the stock tranny!
Range120 Miles (193 Kilometers)
120 miles to full discharge, 95 miles to 80% DoD
and driving normal.
Watt Hours/Mile220 Wh/Mile
190 when driving like your grandma, 220 when
driving normal, and 250 when driving
aggressively. All those tests were done in warm
weather. In cold weather it is significantly
EV Miles
Current:2,000 Miles (3,218 Kilometers)
Seating Capacity2 adults
Curb Weight2,400 Pounds (1,090 Kilograms)
Conversion TimeAround 3 months for conversion, 6 months for
Conversion CostApp $16k for conversion, $4k for restoration
Additional FeaturesToyota Prius throttle, Coil over rear shocks, Kennedy stage III
clutch, 4 puck ceramic disc, individual volt meters on each cell,
temperature sensors for each battery pack and motor, Volante steering
wheel, Home made traction bar to prevent the motor from sagging too much on heavy acceleration and possibly bending frame horns and also preventing wheel hop.
Using a Warp 11 DC motor for a car this size seemed like overkill,
but why bother doing a conversion if its not going to scream? It has
unbelievable torque at low rpm. It burns rubber in 2nd and even 3rd
gear. But I was surprised by how much more pronounced the effect from
back EMF is, which begins at a lower rpm and is stronger. However,
driving all the time in 4th gear keeps rpms low, solving that problem
(motor heating hasn't been an issue either, because this giant motor
doesn't even seem to notice this little car! It runs much cooler than
the Warp 9 in my bug). The Ghia is much more stable and quiet at 90
mph than the bug.
Most components were purchased from EV West. Very good customer
service. The controller was from ZEVA -- amazing customer service.

code by jerry