I like your approach to research and detail. Please keep posting here to show off your progress.
I've always wanted a C3 Vette, and I've liked the idea of doing an EV conversion of one for years. But instead I cheaped out and went with a poor man's Vette, the Opel GT. (If you're curious, thread here: https://www.diyelectriccar.com/forums/showthread.php?p=1046563 ). I'll be watching your build vicariously as the higher-budget higher-class upgrade I kinda wanted to do instead.
...
I think it's prudent to not be overly prescriptive of what you necessarily want, unless you're passionate about certain build details. Rather, figure what you want for performance, and then fill back on the stuff that can make that happen. You might be doing that, I'm not sure, just a general warning that you don't put the cart before the horse because maybe you'd be happier doing things a different way.
Donor: Love it.
Budget: $35k is enough to give you some options.
Motor: I have a feeling you're kind of set on something this powerful, or that you'd rather not bother. So, that's cool, you can make this work and your layout seems to work for the powertrain. Budget will be eaten significantly, but, it's a good foundation for the rest of the build.
Batteries: You're going with the most expensive drivetrain, and the cheapest batteries. There is nothing wrong with Volt batteries, except that they're overbuilt. That is, they are bulky and heavy for their energy density. That's going to hurt performance and range. They are cheap though. It's really the only other way to keep your budget down though, as it's usually the single most expensive component.
You're better off with Volt packs than, say, Leaf packs. But unless you're finding something less popular, Volt and Tesla are kind of the two options for you, and you might not be able to afford Tesla.
Battery prices for salvaged OEM packs may continue to fall in the future, so, if you're planning on being done in 2 years, you might want to hold off and just make the purchase later. Some of us (me, I think) kinda talked too much about how great Volt packs are for off-grid storage and their prices are double what they were a year ago, but generally I think other packs should become cheaper. You could even design for a specific form factor and just make the purchase last minute.
Cooling: Generally cooling is nearly a non-issue, and can be solved by just about anything. A half-assed plan is fine, you'll just "do something" when the time is right, and it'll take a bit longer than you hoped, but, not a lot to worry about.
Controller: The drive unit for the tesla comes with a controller of sorts. You might as well use it rather than spend $3500 on another controller. I think Damien (EVBMW.com) has a kit you can build yourself that can control Tesla drivetrains.
Contactor: Anything, solve it when you solve it.
Power steering: Re-using one but electrically powering the hydraulics is fine.
A/C: You could just plumb one from another EV, but, it's not essential to the car working, so, maybe plan for it space-wise but otherwise upgrade it when you want it.
Charger: You might have to scale back your expectations on how fast you can charge on the road.
Safety: Safety line is a good idea. Your battery pack fuses, sure.
I've always wanted a C3 Vette, and I've liked the idea of doing an EV conversion of one for years. But instead I cheaped out and went with a poor man's Vette, the Opel GT. (If you're curious, thread here: https://www.diyelectriccar.com/forums/showthread.php?p=1046563 ). I'll be watching your build vicariously as the higher-budget higher-class upgrade I kinda wanted to do instead.
...
I think it's prudent to not be overly prescriptive of what you necessarily want, unless you're passionate about certain build details. Rather, figure what you want for performance, and then fill back on the stuff that can make that happen. You might be doing that, I'm not sure, just a general warning that you don't put the cart before the horse because maybe you'd be happier doing things a different way.
Donor: Love it.
Budget: $35k is enough to give you some options.
Motor: I have a feeling you're kind of set on something this powerful, or that you'd rather not bother. So, that's cool, you can make this work and your layout seems to work for the powertrain. Budget will be eaten significantly, but, it's a good foundation for the rest of the build.
Batteries: You're going with the most expensive drivetrain, and the cheapest batteries. There is nothing wrong with Volt batteries, except that they're overbuilt. That is, they are bulky and heavy for their energy density. That's going to hurt performance and range. They are cheap though. It's really the only other way to keep your budget down though, as it's usually the single most expensive component.
You're better off with Volt packs than, say, Leaf packs. But unless you're finding something less popular, Volt and Tesla are kind of the two options for you, and you might not be able to afford Tesla.
Battery prices for salvaged OEM packs may continue to fall in the future, so, if you're planning on being done in 2 years, you might want to hold off and just make the purchase later. Some of us (me, I think) kinda talked too much about how great Volt packs are for off-grid storage and their prices are double what they were a year ago, but generally I think other packs should become cheaper. You could even design for a specific form factor and just make the purchase last minute.
Cooling: Generally cooling is nearly a non-issue, and can be solved by just about anything. A half-assed plan is fine, you'll just "do something" when the time is right, and it'll take a bit longer than you hoped, but, not a lot to worry about.
Controller: The drive unit for the tesla comes with a controller of sorts. You might as well use it rather than spend $3500 on another controller. I think Damien (EVBMW.com) has a kit you can build yourself that can control Tesla drivetrains.
Contactor: Anything, solve it when you solve it.
Power steering: Re-using one but electrically powering the hydraulics is fine.
A/C: You could just plumb one from another EV, but, it's not essential to the car working, so, maybe plan for it space-wise but otherwise upgrade it when you want it.
Charger: You might have to scale back your expectations on how fast you can charge on the road.
Safety: Safety line is a good idea. Your battery pack fuses, sure.
