Others here probably can.
If you couldn't tell, I don't need them, so don't have bookmarks or a collection of these.
If you couldn't tell, I don't need them, so don't have bookmarks or a collection of these.
1961 Volvo PV 544 to EV 544 - Build Thread
Hello All!
I pondered what to do to this car for over 1 year since driving it home. Yes, it was the first project car I had not needed a trailer for! I have travelled as far as Southern Cal. to pickup other projects with a trailer in tow. Never one only 15 miles from home! And so cheap ($2500) for a running vintage car!
Because the starting point was so favorable, it was tempting to simply do a stock restoration. But then I started digging and found the engine and tranny were not original, coming from a newer Volvo. I felt like it opened the door for a restomod. I am soon 72 years old and have always enjoyed a challenge. My last build was a traditional hot rod which included at totally fabricated frame and flat head V8. Parts were either already in my shop or sourced from multiple swap meets and online sales The various parts spanned years 1928 to 1962 in vintage. I also upgraded a 1958 MGA Coupe to a 2000 Miata drive train. I have done a 1956 F100 PU with a 90's era drivetrain from a T-bird SuperCoupe. This past May I drove Rte. 66 in it. 6000 miles round trip. So major technology jumps with previous projects has been accomplished. And I drive the things! But ICE to EV??? Before last year I didn't even know what those acronyms stood for!
I reviewed the topics I was to cover with my first post, and I can see the logic to determine where everyone enters this EV game. So I can fabricate, I can visualize, I can drive. But this EV thing was a bit intimidating. Then I took a ride in a modern EV and got sucked in! With your help, I hope to make this car an almost daily driver. I am planning for 80 - 100 mile range. I also want to approach this incrementally, both for affordability, but also because I like to mock up restomods to present a car look like it could have come from the factory that way. I have become adept at doing this, but it has always been by trial and error with lots of cardboard and wood mock-ups. I have fabricated things multiple times to get it looking right (as well as for structural integrity!).
I hope I can present this EV conversion similar to my other less radical projects. I want the motor with controller to take center stage, so no battery box on top of it, even though there is a lot of room under the bulbous hood. Likewise, I doubled the HP and Torque on that MGA mentioned above, and it suddenly became a fun (not to mention dependable) sports car! While I will only have a marginal HP jump in my chosen EV gear, I am pretty sure the torque value and dependability factors will be satisfying enough!
That all said, I have been working with EVWest to gain a system understanding and with a local Electrical shop that has dabbled in EV development for the last 10 years. EVWest had done a Volvo P1800 several years ago and just this past week we were able to confirm a match to my Volvo bellhousing and flywheel. So I have the adapter/coupler on order with them. I also have a Hyper 9 HV motor system with chill plate and front motor mount on order with the local shop. Saved much on freight by finding a local source for that! I have other components pre-selected from both EVW and locally, but again will use these first major pieces to anchor the mock-up stage. So because the adapter is a long lead item, I will probably be doing more restoration type stuff in the interim, so bear with me.
I attach pix of the car, the voluminous engine bay and similar trunk. I do plan to put at least some battery packs in the rear where the gas tank came from. However only 100-120 lbs or so to help keep within original weight trim. Which I think will be okay, with so much room in front. But again, I want to showcase the motor. Not the battery packs.
Looking forward to hearing comments from this valued knowledge base in the months ahead!
![Wheel Tire Car Vehicle Motor vehicle]()
![Hood Motor vehicle Automotive tire Automotive exterior Vehicle]()
![Motor vehicle Vehicle Car Automotive design Gas]()
John Larsen
Lynden, WA
USA
I pondered what to do to this car for over 1 year since driving it home. Yes, it was the first project car I had not needed a trailer for! I have travelled as far as Southern Cal. to pickup other projects with a trailer in tow. Never one only 15 miles from home! And so cheap ($2500) for a running vintage car!
Because the starting point was so favorable, it was tempting to simply do a stock restoration. But then I started digging and found the engine and tranny were not original, coming from a newer Volvo. I felt like it opened the door for a restomod. I am soon 72 years old and have always enjoyed a challenge. My last build was a traditional hot rod which included at totally fabricated frame and flat head V8. Parts were either already in my shop or sourced from multiple swap meets and online sales The various parts spanned years 1928 to 1962 in vintage. I also upgraded a 1958 MGA Coupe to a 2000 Miata drive train. I have done a 1956 F100 PU with a 90's era drivetrain from a T-bird SuperCoupe. This past May I drove Rte. 66 in it. 6000 miles round trip. So major technology jumps with previous projects has been accomplished. And I drive the things! But ICE to EV??? Before last year I didn't even know what those acronyms stood for!
I reviewed the topics I was to cover with my first post, and I can see the logic to determine where everyone enters this EV game. So I can fabricate, I can visualize, I can drive. But this EV thing was a bit intimidating. Then I took a ride in a modern EV and got sucked in! With your help, I hope to make this car an almost daily driver. I am planning for 80 - 100 mile range. I also want to approach this incrementally, both for affordability, but also because I like to mock up restomods to present a car look like it could have come from the factory that way. I have become adept at doing this, but it has always been by trial and error with lots of cardboard and wood mock-ups. I have fabricated things multiple times to get it looking right (as well as for structural integrity!).
I hope I can present this EV conversion similar to my other less radical projects. I want the motor with controller to take center stage, so no battery box on top of it, even though there is a lot of room under the bulbous hood. Likewise, I doubled the HP and Torque on that MGA mentioned above, and it suddenly became a fun (not to mention dependable) sports car! While I will only have a marginal HP jump in my chosen EV gear, I am pretty sure the torque value and dependability factors will be satisfying enough!
That all said, I have been working with EVWest to gain a system understanding and with a local Electrical shop that has dabbled in EV development for the last 10 years. EVWest had done a Volvo P1800 several years ago and just this past week we were able to confirm a match to my Volvo bellhousing and flywheel. So I have the adapter/coupler on order with them. I also have a Hyper 9 HV motor system with chill plate and front motor mount on order with the local shop. Saved much on freight by finding a local source for that! I have other components pre-selected from both EVW and locally, but again will use these first major pieces to anchor the mock-up stage. So because the adapter is a long lead item, I will probably be doing more restoration type stuff in the interim, so bear with me.
I attach pix of the car, the voluminous engine bay and similar trunk. I do plan to put at least some battery packs in the rear where the gas tank came from. However only 100-120 lbs or so to help keep within original weight trim. Which I think will be okay, with so much room in front. But again, I want to showcase the motor. Not the battery packs.
Looking forward to hearing comments from this valued knowledge base in the months ahead!
John Larsen
Lynden, WA
USA
121 - 140 of 187 Posts
Actually, I suggested a big block, not an SBC. Yeah, LS rules these days, but not in my lifetime. I have an old Ford PU with a more modern supercharged V6 in it though. Same for my 58 MGA coupe with a 2000 era MX-5 engine in it. I figure this EV conversion is going to match those for fun and comfort.
Well, maybe not the old truck...it has all independent suspension from a T-bird and a Jaguar. It rides and handles like a sport sedan! AND includes all the inherent safety features of those vehicles! Yes, including an inertia switch.
And the MGA? To the old timers at this British car show, it might as well have been an EV! Probably the only one there with an OBDII era computer system. Safe? Uh, not really, although I did add disc brakes to counter the extra HP.
![Wheel Tire Car Vehicle Land vehicle]()
![Hood Car Motor vehicle Vehicle Automotive design]()
Well, maybe not the old truck...it has all independent suspension from a T-bird and a Jaguar. It rides and handles like a sport sedan! AND includes all the inherent safety features of those vehicles! Yes, including an inertia switch.
And the MGA? To the old timers at this British car show, it might as well have been an EV! Probably the only one there with an OBDII era computer system. Safe? Uh, not really, although I did add disc brakes to counter the extra HP.
I went to a safe haven and almost completed the 12V system today, upgrading the old fuse box that had broken cardboard backing falling off along with antiquated ceramic fuses.. Having put the EV controller on the old battery shelf in the firewall, I have relocated the 12V battery to the trunk (boot) and ran 6 ga cable to the front ignition switch. Total amp draw on the 12V fuse box may be 30 amps after I add a cooling fan for the controller radiator. (That's with all accessories turned on.) Should have plenty of capacity for the LV/HV circuits. The original wiring on the Volvo was in good shape, plus it was sized for 6V with 25 amp service, so it is extra heavy wire gauge for 12V at 30 amp.
Cant put off the HV wiring much longer...
![Musical instrument Motor vehicle Automotive lighting Gas Hat]()
![Motor vehicle Automotive lighting Electrical wiring Gas Auto part]()
![Motor vehicle Electrical wiring Automotive lighting Circuit component Gas]()
Cant put off the HV wiring much longer...
Yeah, I figured between the two of us, we could find someway to make a 12V system unsafe...or at least come up with a Fed regulation to make it totally unwieldy in the least.
Go back to post #107 for the DC-DC location. Sheesh Remy, if you can't keep up, take notes for crying out loud!
Go back to post #107 for the DC-DC location. Sheesh Remy, if you can't keep up, take notes for crying out loud!
121 - 140 of 187 Posts
