Hello fellow EV enthousiasts!
Here is a new forum member from Holland (officially: The Netherlands) introducing his first(?) EV project. Just completed the thing after 4 months of building time and awaiting the official scrutineering of the state transport authorities (known as the RDW).
The base ICE car is a DAF 33 from 1974. This was our national pride -the only seriously produced passenger car in holland- between 1959 and 1975. Then Volvo bought the whole lot and axed the smaller models. Although they continued to make the very last DAF-developed car the ''volvo 340'' until 1992. Including the version with DAFs unique feature: the continuously variable transmission called Variomatic. This was a rubber V-belt transmission system which worked 100% mechanical without any hydaulics or electrics, just the forces of nature (spring and centrifugal force, some inlet vacuum and the tension in the belts itself). Therefore ideally suited for conversion. Also because the smallest DAF model only weighs 660 kg, can be loaded up to 990 kg, and has a huge trunk for its total size. No powered options just all mechanical brakes, steering etc.
So i performed the usual steps: removing all the oily bits, cleaning the engine bay from 42 years of oil spilling and exhaust soot, constructing the battery pack and motor controller box, and rewiring the whole lot. Straightforward job for an old car tinkerer, all parts were plug&play. Just had to construct some smaller stuff like engine adapters, the vacuum control for the CVT (now using an electric pump) and an alternative defroster since the ICE was aircooled and the surplus heat was originally used for this purpose.
The following components were used for this conversion:
AC elmo 15 kW - 50 Nm at 48V; complete sealed controllerbox with Curtis controller, DC/DC converter etc (due to european regulations you are not allowed to use anything else than this with EMC certification from the supplier); 16 x Sinopoly 3.2V LiFePO4 battery cells with BMS system; 240 VAC single phase battery charger for home charging use (ordinary wall socket).
The projected performance of the car is: range 60 km; top speed 85 km/h. It accellerates a lot quicker to 50 km/h than before but due to the difference in power (originally 34 BHP = 25 kW) the original top speed of 115 km/h is not reached. Since i will not use it on highways this is not important. My round trip to work is 40 km so this is sufficient. It's a fun car only for summer use, i've still got another (larger) DAF CVT fuel engined car for winter and longer hauls.
The use of a relatively weak engine and humble battery pack is made possible by the Variomatic. You can't use these with a 1:1 fixed transmission setup. The CVT will always select the optimal reduction ratio at any moment so the E motor will be minimally stressed. In practice this proved correct, it uses 12 kWh on accellerating to 7 kWh at 50 km/h. Flat out it's 16 kWh at 85 km/h. More extensive testing will have to wait until i have the RDW approval.
I'm confident that this is the very first converted DAF 33, and in respectful rememberance of the pioneer that was killed by GM i call it ''EV33''.
Thanx for your interest, best regards from Holland!