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Jack-Lee 06-21-2019 05:14 PM

Smart Roadster EV
2 Attachment(s)
Some may still know me from my VW Polo 86C project. Have not written here for some time, but that should change now. I mothballed my Polo, sold most parts and got a Smart Roadster.

To the project:
Basis is above mentioned Smart Roadster BJ2006. The car is in good condition, no rust or similar.
Installed is a 0.7l turbo gasoline engine with 90hp in the rear. This was also the reason for choosing the vehicle: small, light, rear-wheel drive and affordable. With 810kg empty weight, the car is a flyweight for a Mercedes of this year.
Currently I drive the car with about 3.8l / 100km:

The goal, however, is to convert the car to electric drive. If one estimates the engine's energy efficiency and current consumption as the energy consumption later on, it comes to about 7-8kWh / 100km. The aerodynamics can still be improved MASSIV. A cw value of 0.3 should at least be achieved (currently 0.38). The front surface of just 1.54mē helps to achieve low air resistance.

I originally provided the components for the conversion for my Polo. Therefore, these are too big and too heavy for the Smart (Tesla S 220kW engine + BMW I3 90Ah battery). Currently I am trying to sell these. If this is successful, new components will be provided:
-Motor = EMRAX 228 or 268
Controller = in search
Gearbox = modified smart gearbox
Battery = LG CHEM 350V 17.6kWh 110kg

Will continue to report :)


Stubby79 06-22-2019 12:26 AM

Nice! We didn't get the roadster on this side of the pond...I would have killed to get one! Saw one in person when I was in Rome...dang good looking car, and great gas mileage!

oldtamiyaphile 06-22-2019 08:51 PM


Originally Posted by Stubby79 (Post 600498)
Nice! We didn't get the roadster on this side of the pond...I would have killed to get one! Saw one in person when I was in Rome...dang good looking car, and great gas mileage!

Worst gearbox in history, and an engine life of as little as 60k miles made them less than Smart.

Ideal candidate for an EV conversion though:thumbup:

Jack-Lee 06-24-2019 06:42 AM

The gearbox is slow but very Light and durable and the engine dies because of the driver... Eg He change only three of the six sparkplugs, or press the Pedal to the Metal with Cold oil... My engine has 145000km and works great.

But... Electric is better

Jack-Lee 06-28-2019 01:17 AM

The I3 Battery is sold and i buy a Smart ED4 Battery-Assamble.
120kg for all three Blocks (17,6kWh) without Housing. Little bit higher (175mm instead of 150mm from the BMW I3 Blocks) and with 430x355mm groundaera a little bit larger Modules. I hope i could squeeze them under the rear trunk, above the Engine.

"Fleck Elektromobile", a lokal EV Workshop, means the Roadster get +49kg empty Payload after his convertion. He use a heavy 60kg asynchronmotor with only 30kW and 10kWh LiFePO4 (wight about 110kg). So my Setup with ED4 Battery and Tesla should weight roughly the same and i had no problem with "overweight" :)

freebeard 06-28-2019 10:53 PM

So, 132lb and 40hp? What range is projected for 10kWh?

98lb and 68hp. I wouldn't get one though, I here the later RAV4 has twin motors and 80hp.

I remember this:

Was that 3D printed?

Jack-Lee 06-29-2019 02:04 AM

Yea, 3d printet. The tesla weight about 90kg for Motor, gearing and Controller. Good weight for up to 220kw

Jack-Lee 10-10-2019 02:07 PM

2 Attachment(s)
Long time since the last post.
A lot has happened, the setup has been changed and a second car has been purchased for the conversion phase.
In addition, there was new paint for the car, the first aerodynamic Verbersserungen have arrived and the very low consumption of approximately 3.4l / 100km gasoline shows that the 8kWh / 100km are realistic.

I buy new Cells with 260Wh/kg, so i could squeeze 22kWh in only 95kg inclusive Case, Mountingframe and BMW :turtle:
This weight advantage allows me to switch back to the Tesla engine. Will reduce the power to about 120kW ... but hey, the vehicle weighs only 850kg and I do not have to switch!

PS: i attached a picture to show how tiny this realy cool car is.

freebeard 10-10-2019 05:17 PM


...first aerodynamic Verbersserungen have arrived...
Is that an improvement?

cRiPpLe_rOoStEr 10-10-2019 06:42 PM


Originally Posted by oldtamiyaphile (Post 600528)
Ideal candidate for an EV conversion though:thumbup:

I'd rather try some motorcycle engine conversion instead of going full-EV. Maybe not disconsider some hybrid setup.

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