1967 VW Split Screen Van - "ICE Breaker"
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I'm lowering the bus by about 2" while also fitting larger 16" wheels. I like the slammed look but don't want to cut the bus unnecessarily nor make it impractical for road trips
I'm still some way off from a trial fitting because I must resubmit the bus with ICE for registration in the UK
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Apologies for the 'radio silence' during the last few months, I've been busy on one of my other projects, repairing our watermill
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busy day today... tomorrow I take a look at the two motors
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I'm definitely hooked on this one!
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We've completed all the major repairs and will sell the mill next year... following Brexit we've moved our rnd and production to our US location and have started looking for offices in Dublin. We don't plan to spend much time in the UK in future.
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miscellaneous parts that came with the battery and motors
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I had a quick play with the 'small' Tesla rear motor and my IRS today. It looks as if the motor will fit with only minor reworking of the IRS and leave a huge cavern where the ICE used to be
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Thanks for posting all the pictures! I am envisioning Tesla battery modules nested into the floor of the VW, and the engine space converted to storage.I had a quick play with the 'small' Tesla rear motor and my IRS today. It looks as if the motor will fit with only minor reworking of the IRS and leave a huge cavern where the ICE used to be
Sounds great, but there really isn't much usable volume within the floor structure, so a more likely Tesla-style installation would be to cover the load floor in battery, with a new floor built up on top and seriously compromised interior headroom. Then in the back, the Tesla motor is taking the original engine space, leaving only the transaxle and muffler spaces free... which will be needed for electronics. The original gas tank volume seems like the only potentially gained volume, assuming it isn't needed for more battery (since the floor space is smaller than a Model S battery).
The Tesla motor and transaxle with the aftermarket suspension look really good, but I expect that reality will be a packaging challenge, rather than a storage bonus.
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Our current plan is to modify (replace?) the chassis to create a large area under the floor for batteries. The battery box will be designed to be removed easily for future upgrades. Given the Tesla drivetrain (motor/inverter/transmission) has a similar volume to the ICE transmission we do gain most of the area occupied by the old engine and fuel tank.
We will install two Tesla chargers for 22kW 3 Phase AC charging but they are quite small, and we will need radiators for cooling the motor, chargers, and battery (currently were trying to put the rads up inside the 'cheeks' where the side air vents are located).
Our biggest problem is battery weight... we will use aluminium where possible and install a minimalist interior (which I much prefer not being a fan of curtains
).I'll start recording some vids now that the project is making progress
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We're currently exploring the idea of building a new chassis for the bus. Not only does this allow us to build a much stronger structure using modern materials but it also allows the battery to be placed under the floor and between the wheels.
The chassis centre section (see photo) is approximately 1500mm x 1500mm x 200mm. Each Tesla module is approximately 700mm x 300mm x 80mm. Therfore two layers of eight modules will fit in theory
The chassis centre section (see photo) is approximately 1500mm x 1500mm x 200mm. Each Tesla module is approximately 700mm x 300mm x 80mm. Therfore two layers of eight modules will fit in theory
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Hi Kevin
I thought about using a folded composite chassis for my car before I chickened out
That flat chassis just calls out for a folded honeycomb structure
http://www.paleoneon.com/electriccar.html
I thought about using a folded composite chassis for my car before I chickened out
That flat chassis just calls out for a folded honeycomb structure
http://www.paleoneon.com/electriccar.html
Great info and illustrations!We're currently exploring the idea of building a new chassis for the bus. Not only does this allow us to build a much stronger structure using modern materials but it also allows the battery to be placed under the floor and between the wheels.
The chassis centre section (see photo) is approximately 1500mm x 1500mm x 200mm. Each Tesla module is approximately 700mm x 300mm x 80mm. Therfore two layers of eight modules will fit in theory
The photo of the original floor structure shows the problem: there's volume, but it is broken up into small spaces by structural elements. Thus, the plan for new structure.
If I understand this correctly, it sounds like you're planning to have half the area and twice the depth, to get all 16 modules in. Since Tesla barely fits two modules end-to-end across the width, my guess is that this orientation won't work for the van by the time structure and box are considered, so the layout will be different. It looks like Tesla has an issue with space, too... there appear to be two modules stacked at the front, because they don't all fit under the passenger compartment floor in one layer.
It is popular to show the powertrain, subframes, suspensions, and battery box of the Model S and call it the "skateboard", but this is misleading because it suggests that the battery box is the floor structure (the "board"). It is not - the body structure is all above that (and along the sides as rocker panel boxes), and almost never shown with the "skateboard". The Tesla design is basically a normal unibody car (in aluminum), sitting a few centimetres higher than normal, with a shallow battery box hung under it, and apparently tucked in between the rocker panels. The box fits because it is not competing for space with an exhaust system or fuel tank. The current plan for the van appears to be a shorter, narrower, and taller version of the same approach.
We're currently exploring the idea of building a new chassis for the bus. Not only does this allow us to build a much stronger structure using modern materials but it also allows the battery to be placed under the floor and between the wheels.
The chassis centre section (see photo) is approximately 1500mm x 1500mm x 200mm. Each Tesla module is approximately 700mm x 300mm x 80mm. Therfore two layers of eight modules will fit in theory
That is perfect. I was going to say that I think you have the space based on this pic.
If need to you could go a bit lower than the bottom of the stock frame and then gain that clearance back with taller tires.
You will want to end up with a flush bottom for reduced drag. Having that bottom be structural will greatly enhance chassis rigidity and allow you to have removable floor panels to access your packs for maintenance.
Great to see a project with the battery where it should be.
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It's clear the volume exists to build a two layer battery box under the floor and between the wheels... I can even use the same basic layout as Tesla with HV busbars along the centre and cooling along the outside edge.
For the record the Tesla Model S battery box is 1460mm wide (ignoring the side mounting brackets) and four modules requires ~1260mm
All I need now is a chassis fabricator who can deliver in a decent time period
For the record the Tesla Model S battery box is 1460mm wide (ignoring the side mounting brackets) and four modules requires ~1260mm
All I need now is a chassis fabricator who can deliver in a decent time period
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