Several months ago I purchased a donor car and have been spending my time reading this forum and stripping the car and getting ready for the conversion.
I am a 60 + retired financial executive. I have owned 4 VW’s over the years and in college my brother and I rebuilt the engine on a bug convertible. I have good mechanical skills and am an electronic hobbyist. Some time ago I installed a 3KW solar PV system on the roof of my home. I have also converted 2 bicycles to electric drive and six months ago I converted one of them to Lithium (48v Headway pack). My desire for more speed and utility led me to considering an EV conversion.
I have no metal fabrication skills except for the ability to cut, drill or shape aluminum with a router.(derived from my woodworking skills) I have found a local source for aluminum plate and several resources for aluminum welding.
I hope initially to have a range of approximatley 10- 20 miles. I will probably start out with a 96v pack of about 100Ahrs. I expect to get 25 mile range for local driving. Phase two of my plan is to upgrade by paralleling another 100Ahr pack. At that point I should be able to take short trips of 40 miles on the freeway. My choice of 32 cells is driven by the investment I have made in some cellogs and a circuit board by rwaudio that will give me LVC and HVC. When I upgrade to the extra capacity I will probably purchase a high amperage charger and a BMS. In the meantime I can charge slowly with a couple of 48v Meanwells.
My initial budget to get the car running for phase one is $15,000. That includes the AC-35 system which I will pick up inin Ontario, California tomorrow. I ordered the motor and adaptor from Thunderstruck Motors in Santa Rosa CA. and recieved a lot of offline help from Frodus and Gottdi. I have received a quote for 100 Ahr CALB cells from Keegan Han and will probably commit that purchase by the end of June. Later in the year I will evaluate the budget for phase two. The car is currently grey primer with the rear fenders, apron and rear hood removed. I am also considering fiberglass fenders, apron, rear hood and trunk.