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Suzuki Cappuccino Conversion

40048 Views 96 Replies 11 Participants Last post by  tylerwatts
Hi all.

I’ve been lurking on these forums for quite a while but I have finally begun a conversion.

The donor is a 1994 Suzuki Cappuccino. For those who don’t know it’s a tiny Japanese kei sports car weighing around 725kg stock. It comes with a 660cc 3 cylinder twin cam turbo engine as standard in front engine RWD layout. Great fun to drive even with its 64hp power output.

I have begun work on the car to get it ready for the conversion. They all have a problem with rusty floors and although mine is a good example it needs some welding before I can go any further.

I have one of the Enova 90kW AC induction motors which I have been able to get turning on the bench using Damien’s combi control PCB controlling the original Enova power electronics. The plan is to connect the motor directly to the prop-shaft for direct drive (diff ratio is 5.125:1). I believe this should give me pretty good performance considering the motor has around twice the power of the stock ICE.

Recently, I obtained some Boston Power Swing 4400 batteries. They have been used but seem to be in pretty good condition. I have around 20kWh in total but I’m unsure whether I will be able to fit them all in! I will be using the car for my commute which is 19 miles each way. I can charge at work but would like to be able to get there and back comfortably on one charge so I’m aiming for a 50 mile range.

The biggest unknowns at the moment are the charger and BMS options. I need to do some research on this as this is the area I know the least about and seems to be the biggest minefield!

I’ll try to keep you updated with progress and I’m sure I will have plenty of questions!

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Just this but another of legion projects online that generate a lot of hype and interest and respect only to stall near the finish line and never be completed?

As someone who would want to make a Hayabusa V8 Cappuccino but never will, seeing an EV Cappuccino generates much respect and interest.
I hope not! I’m still slowly progressing with the project but I’ve not been very good at updating this thread.

The motor is now mounted and connected to the wheels. The inverter is also in place. The interior has also been refitted now that the rust has been sorted and the floor repainted and waxoiled.

I have been trying to decide where to put the batteries. I was considering spreading them throughout the car (possibly under the floor) so that I can keep the passenger seat. However, I think that I’m going to stick with the original plan of filling the passenger seat area. It will be much easier and hopefully allow me to get the car on the road quicker.

Next jobs are to design and make the battery box as well as getting the pumps and other ancillaries mounted.

I’ve attached a few photos of the progress.

PS. A Hayabusa V8 Cappuccino sounds interesting! Two hayabusas side by side?
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Any chance that Santa is bringing an update soon?
You know that we are all so very much looking forward to the progress. So many projects start but never find completion.
If you can have the AT lever in the stick location, that could create great fun to the unsuspecting with your sleeper. AT kei power and then...wheeeeeeeeeeeeeeeeee you're gone!
Videos should be here:!Am-VyIvBzOs6g80VvC8oEZoAhPBGgw

The bleeping in the first video is the battery low voltage alarm which I had disabled before the second video as it was getting annoying! The JLD404 hasn't been setup properly yet hence the incorrect amp reading.
Something went wrong......!59029&authkey=!ALwvKBGaAITwRoM
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