VW Transporter T5 Van EV conversion.
Here's a picture of said van:
http://ecomodder.com/forum/attachmen...1&d=1440205252 Now, I really love this van. Part of the reason I love it though is the 128kW/400Nm 5 cyl engine. It rockets to 60mph in around 9 seconds. It handles great, rides Ok and is very comfortable. Kerb weight is listed as ~3800lbs, my payload might push that up to 5000lbs max (I figure there must be 400+lbs in the ICE, fuel and ancillaries). I'd like a 60mph top speed and I need 60 miles of range, however I only really need to do 40mph max most days and usually only drive 30 miles per day, with a lifetime average speed of 20mph. I do want to keep the current level of acceleration that makes this van so fun at traffic lights (if not better it:D). I know there are motors out there that can do this. The van is currently rated to tow 4400lbs, and I'm guessing that as long as I use the gears, that shouldn't be a problem (range reduction aside). My main question is how much battery do I need (in terms of Wh, cost and physical size? I've done some research, but most of what I've found is a few years old and obviously battery costs keep falling. Do I use average speed in range calculations? My GPS also stores my moving average which is probably more appropriate (I don't remember this off hand). I figure if I no longer care about the current ICE and just run it until it dies, it lets me save up in the mean time, batteries will only become more affordable, and I've got time to get the A/C, power steer etc EV ready while I wait. |
Wow, $18k to fix the cylinder head!? That's ridiculous. Love the plan, though... subscribed.
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I'd probably rather drop an Isuzu 4JH1 as a replacement to the 5-cyl TDI and call it a day. Anyway, if you're really into converting the van into an EV, I'd suggest you to consider turning it into 4WD with a direct-driven motor at the rear axle.
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The Isuzu makes less power and torque from a bigger engine, and in the Rodeo is thirstier. A backwards step in my book, reliability counts for something though.
Admittedly my mechanical skills aren't great, and I feel more likely to complete an EV conversion than I would an engine swap (plus there's actually an EV converter near me if I really get stuck). Ideally, I'd fix the head myself, but I wonder if that's a smart move if Euro and VW specialist mechanics don't want to touch it. Back to the EV conversion. I used 8l/100km on my last tank (about average). I figure about 1l/100km is wasted idling (I don't like to shut down my turbo cars repeatedly), so we should have a safety margin. The EM calculator tells me that equates to 710Wh/km. I want to travel 100km on a charge so I need a 71kWh pack. This is at odds with the EV source calculator which predicts a nearly 60 mile range on a 28.8kWh pack. They don't factor in that I drive all low speed streets and would be hypermiling, I expect I would see a healthy 80miles on such a pack. This pack will cost $12K and weigh 700lbs. My van has a good amount of space under the floor so all the batteries would be mounted below my CG, improving ride and handling (maybe!). How would I more accurately predict my required capacity based on my current diesel usage? |
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Based on 3800 lbs a decent conversion should get you 380 w-h per mile. A bad conversion maybe 450 w-h per mile. A Great conversion 350 w-h per mile. Do you run cargo or towing a lot? If not, I would not put the extra weight into your nominal calculations. With low-speed driving and hyper-miling, running an AC system and using regen to stop at lights (when coasting in traffic just won't cut it) I'll bet you could beat 350 w-h per mile. Quote:
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Thanks for the input. I think 4400lbs is about right for a typical loaded van with the expected added weight of the conversion factored in. I have a 1000lbs trailer that I tow quite often, but I plan on building a lighter 6-700lbs version soon. I could fit a generator to the trailer for occasional last resort use. The EV calculator predicted range doesn't change as much as I expected when I play with the curb weight. From 3800 to 5000lbs reduces range by 14 miles, which typically won't be the end of the world. Quote:
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I'm surprised there isn't an established formula for converting fuel use to electron use. It would surely be more effective than using vehicle weight as the only input, ignoring aero drag and required speed. If a heater wasn't a legal requirement, I would probably not bother fitting one. Is it more common to run DC:DC converters or to retain separate 12V batteries? I'm thinking my 12V battery would be grid charged and sized to match my EV range, my 12V usage wouldn't affect my range that way. The roof has space for ~500W of solar panels which would probably be enough for my 12V requirements. |
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