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  #1  
Old 04-15-2017, 04:05 AM
gromsound gromsound is offline
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Default Introducing: the DAF EV33 from Holland

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!
Andre.





Last edited by gromsound; 04-15-2017 at 04:10 AM. Reason: pics
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  #2  
Old 04-15-2017, 05:28 AM
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alvin alvin is offline
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Default Re: Introducing: the DAF EV33 from Holland

Welcome. That looks very nice. I would like to see an AC Elmo.
Good luck with the RDW.

Alvin
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Old 04-15-2017, 05:44 AM
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kennybobby kennybobby is offline
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Default Re: Introducing: the DAF EV33 from Holland

That's a great project thanks for sharing such a unique build.
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Old 04-15-2017, 05:55 AM
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Nabla_Operator Nabla_Operator is offline
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Default Re: Introducing: the DAF EV33 from Holland

Great little car you have there, Andre.
Next week (april 22nd) DAF club Holland shows a model 66-EV, converted by University of Ostfalia (Braunschweig) in Geldrop (NL).
I want to go there; hope to meet you there.
--paul--
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Old 04-15-2017, 09:31 AM
gromsound gromsound is offline
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Default Re: Introducing: the DAF EV33 from Holland

Hi Paul

yep i know, was finishing my build when the news from the German EV colleagues came (they have used the same kit by the way, of course with larger capacity). Well at least i am the first in holland and with a daf 33..

can't come to Geldrop, too far away sorry.

Last edited by gromsound; 04-15-2017 at 09:32 AM. Reason: typo
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Old 04-16-2017, 12:04 AM
oudevolvo oudevolvo is offline
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Default Re: Introducing: the DAF EV33 from Holland

Wow, nice project and quite short turnaround time.
Have you already been to Lelystad and are you awaiting your updated papers? Or do you still need to go to the inspection?
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Old 04-16-2017, 01:48 AM
gromsound gromsound is offline
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Default Re: Introducing: the DAF EV33 from Holland

Hi there

The application has still to be sent out, i'm now finetuning the last details in the electric diagram for the RDW. I understood from the experienced builders that the complete paperchange will take several weeks (there's only one location specialised in EV testing and they do all other home built vehicles too). So hopefully i can get to the road (legally) this summer.
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Old 04-18-2017, 07:26 AM
Moltenmetal Moltenmetal is offline
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Default Re: Introducing: the DAF EV33 from Holland

That's a very cute car and a great project, especially with the history thrown in. This is the only sort of car worth converting now, since the option to just buy a commuter EV is pretty straightforward now.
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Old 04-18-2017, 05:11 PM
Karter2 Karter2 is offline
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Default Re: Introducing: the DAF EV33 from Holland

Very neat conversion to a classic vehicle.
Im sure you have checked, and i note the power draw flat out, but are you certain your max speed is not motor rpm limited ?
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Old 04-19-2017, 09:31 AM
gromsound gromsound is offline
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Default Re: Introducing: the DAF EV33 from Holland

Hi again, thanx for the support
Yup the supplier even fine tuned the motor field parameters (by laptop connection) during driving flat out until the max was found. Then we got it up from 82 to 85 km/h that's all there is.
On the plus side, you can still move 3 adults and some luggage around. And for my usual drive it is sufficient. In city traffic the little dafs were always among the quickest thanks to the CVT (you can't switch gear that fast unless you are some kind of racing trained driver), but now on electrons its even quicker. Real fun!
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