[dspl1236]

So this is my project space for the 1990 Jetta to 2014 Cadillac ELR powertrain swap. I normally do engine swaps in various VW/Audi platforms. I wanted to try something new entirely. The biggest hurdle I have found if the motor controls and I am hoping Eldis will pull through with his UMC project....

So this Jetta was getting setup for a 2010 GTI 2.0 TSI swap and to be the first in the US to complete the swap. Custom flywheel, ecu was hacked to run standalone. Anyone can do the mechanical swap...but no one around here in Ohio does electric swaps...so this is my challenge.


Parts I have:
- '90 Jetta
- '14 ELR transmission 5k miles
- '14 ELR Inverter 5K miles
- Lots of 18650 cells in testing.

Goal:
Build a 370v 10Kw 18650 battery setup, then keep adding 10kW packs. Ultimately would be able to do 500mi trips.

Next to a 2004 VW R32 6 speed awd transmission

 

[dspl1236]

Well looks like I will be going with P&S Power Electronics AC Motor Controller.

 

[Duncan]

Hi - fun project!
10 kilowatt hour (don't forget the hour) will give you roughly 30 miles

500 miles is probably not doable as you will be well into the increasing weight diminishing return game at that point - not to mention space to put the packs!

 

[Karter2]

What 18650s are you using ?
A 370v , 10kWh pack will need approx 1000 cells , presumably in 100s , 10p configuration. Thats a lot of pack building etc.
Unless you have some very special cells, you wont be able to get much more than 20 kW peak from that pack !

 

[dspl1236]

Hey guys! It is an ambitious project. I am used to just adding bigger turbos, fueling and ecu tuning...this is a all new ball game lol. They way I look at is that this where we are going and I might as well understand and build my own car to really understand the fundamentals. I am always open to suggestions and pointers as I see no one really has finished a swap like this. Mechanically this is a super easy swap.

Building the first 1k 18650 pack now and it is a slooow pace. Using recycled laptop batteries for the first pack, then I will buy cells. Each 1k pack will weigh about 100lbs minus the bus bars. Plan is 100s10p. I go to alot of east coast car shows and plan on taking the Jetta in the next year. For the range I may build an extended range trailer with its own charger...but we will see.

I was originally looking at Leaf and other powertrains till I saw the GM 4ET50. Man is it slick...and complicated. Super robust, 30% detuned from the factory. But I will simplify its operations, then add functionality in time.
I am suspecting a top speed of 110mph with a 0-60 under 7 seconds in a 2700lbs car. Gear raitos in the 4et50 are interesting as is seems could be infinitely adjustable if you operated the motors independently. My machine shop neighbor want to build the same setup but with an old mechanical vw diesel as a generator as I want to run this ICE free.

 

[Yabert]

IMHO, when you will have learned many thing by building your fist battery out of crappy low power laptop cell, you will enjoy to discover than the chevy Volt battery is also detuned.
http://www.diyelectriccar.com/forums/showthread.php/power-capability-chevy-volt-battery-109698.html

Or that the Tesla modules are useful too.