Paul & Sabrina's Cheap EV Conversion

[metromizer]

The later model (like yours) ACVW's have a couple switches threaded directly into the body of the master cylinder. Are you saying they aren't? If not, what are you using as plugs? If they are still intact, in the M/C and they don't work or are not connected to anything, don't give up and replace them, those seldom fail.

Check them with a VOM or test light after you remove the connectors (isolate the switch, have someone step on the brake pedal for you while you have the VOM connected)

[MPaulHolmes]

The 2 switches are threaded into the master cylinder. They are both covered by a pretty new looking rubber cover. I'll see what can be done tomorrow. I'm going to try your suggestions, Metromizer! Thank you!

[bbjsw10]

Paul, that is awesome I have always wanted a bug, plus electric powered. Drooling as I type. Wish I had the money for the one in town, great shape for a 68 and only $750 and runs/drives. Could sell the motor and alot of parts to recoup that money but don't have the $750 to start with.

[MPaulHolmes]

Originally Posted by bbjsw10

Paul, that is awesome I have always wanted a bug, plus electric powered. Drooling as I type. Wish I had the money for the one in town, great shape for a 68 and only $750 and runs/drives. Could sell the motor and alot of parts to recoup that money but don't have the $750 to start with.

That's a really good price! Our car was cheap, but there were some reasons why it was so cheap (it was really crappy, and belonged to old people that wanted it gone). I love VW's too. When I bought one about 4 years ago, everywhere I drove, little kids would always point at us. I never knew that until I drove one.

You should keep looking around until you find one abandoned that hasn't driven in a long time. Maybe you can get one for a couple hundred? Do you have anything to hawk? That's what I did to get the $200 together.

Even if the motor is gone, I hear that the transmission is often still good. Then, to fix the brakes is actually really cheap (they will probably be bad). They are pretty easy to work on if you get a good book. I have never done ANY work on ANY car in my life before this project. I didn't even know how to change the oil.

[MPaulHolmes]

Yo, Metromizer! I followed your lovely advice, and I now have working brake lights! It was sort of hard, but they work perfectly now! I was just about to go out and buy a new switch. The switch turned out to be good. I think it was corroded terminals.

[Tango Charlie]

Paul, I have enjoyed your thread immensely. My gut is hurting from laughing so freaking hard.
It's really cool to see someone without a lot of mechanical experience jump with both feet into a project like this.
Glad to hear you got the brake lights working. Now Oprah won't rear-end you.

[bennelson]

Brakelights fixed?

That means you can go make a driving video!!!

[MPaulHolmes]

Make a driving video! Ya!!!!!! Oh, I am so happy right now. Tomorrow, the insurance begins! They don't know it's electric. I'm so sneaky. Lee Hart (the gangster mac-daddy of EVs) said that in an accident, the insurance company needs to prove that the modifications were a part of the CAUSE of the accident. So, I'll just make sure no modifications cause any accident.

I did a laundry list of little things today on the car. First, I did the laundry by placing the entire car inside of a washing maching. Second, I cut out a piece of metal, and covered the vent that runs into the trunk (I JB welded it), so it wouldn't rain inside the trunk anymore. I added a (freewheel) diode from - to + across the contactor's coil. I had forgotten about that. Fortunately, the inductive kick didn't kick anything that I know of. I beat that inductive kick like a read-headed stepchild.

Next, I started to make the splash shield under the motor. I'm gluing a big rubber mat to the piece of wood in the video. Next I have to attach it to the sides. I'll take some pictures of that later.

Then, I added a spring to re-enforce the closing of the gas pedal when my foot is off of it (oops, closing of the the thingy). I did that because I have to add a new spring that keeps the gas pedal stuck to the thing that has a rolling thing on it that is attached to the throttle cable, and that would keep the PB-6 throttle from closing strongly without an extra spring.

I did some thinking about how to get the pre-charge resistor to close by turning the key part of the way. The SCR idea is really energy wasteful. It would work, but then there would be 6 watts running the whole dang time with my specific SCR. Maybe I can add a large gate resistor that keeps the power consumption down.

Also, it needs to be able to conduct at least like 70 amps for 1 second. This is because it took 3 seconds for them to charge through a 2.5 Ohm resistor. So, I may decrease the resistance to like 1 Ohm so it charges in close to 1 second.

But I still need to find a wire that becomes 12v once the key is turned only half way. The radio maybe? I haven't tried that yet.

I bought some new windshield wipers, but I forgot the VW book at my mother in laws house, so they still don't work. Also, the horn doesn't work. I have no idea how to fix either of them. We'll see what happens though.

I JB welded the accelerator pedal back together, since it was broken and kept slipping off of the back rolly thing that pushes the throttle wire back.

I can't remember anything else right now.

[MPaulHolmes]

Oh, Hurray! It's drivable!

[MetroMPG]

Very cool & congratulations, Paul.

Admirable restraint was demonstrated in the face of comments from the first camera operator. Either that or you were concentrating really hard.