[  welcome to my website  ]     what's here:   Electric Vehicles  -   Metal Art  -   Fire Art  -   ...more...    

Expand | Hide
Evan Beloni
About Evan Beloni
Heavy Metal [Art]
Electric VW Golf
Software Development
About Me
Home  |  Technical Information  |  Conversion Process  |  Custom Machining  |  Custom Fabrication  |  EVents

VW Golf electric car conversion process page

Page Selection:
0: Process Home
1: Planning and Procurement
2: Removal of Gas Components
3: Engine Extraction
4: Motor Installation
5: Battery Rack Fabrication
6: Aluminum Mounting Plate
7: Wire Conduit
8: Mounting Other Stuff
9: Battery Interconnect
10: Car Audio

The conversion process was split up into four phases:

(2007 - 06/09)Phase 1was the planning stage and began about a year before the conversion began. This involved selecting the components to go in it, where this would come from, buying the donor car etc.

(7/6/09 - 07/18/09)Phase 2began while I was still driving it as a gas car. This stage simply involved removal of all the gas related components. I began by removing the exhaust system and still drove it around (LOUD) for a couple more days. Then I removed the gas tank and all fuel lines, rendering the Golf undriveable until the conversion was completed. I also pulled out the engine in this stage.

(6/24/09 - 9/10/09)Phase 3was the most complicated and involved phase where all the electric components were installed. I started off by fabricating a battery rack in the trunk area to hold 8 batteries and the charger. The electric motor was fitted with the original flywheel assembly and mounted to the transmission. I also modified the motor mount that came with the motor for a good custom fit to the car. Next, I built a battery rack under the hood to hold 4 more batteries. I mounted all the control components to an aluminum plate on hinges mounted to the firewall with access to the motor. This phase ended the day I successfully drove the electric car.

(9/14/09 - forever)Phase 4is an ongoing phase that includes all the non-conversion specific modifications that I'm doing while the EV is complete.

Work Log

Phase 1100Estimated planning time

Phase 216 total
17-6-09Muffler Removal
47-9-09Remove gas tank, fuel lines, radiator, hoses, almost everything connected to the engine
37-10-09More parts removal
57-18-09Remove engine, other stuff
2.57-19-09Remove most of heat shields, clean engine compartment
0.57-30-09Remove last heat shield
Phase 3108.5 total
105-9-09Mount all components, wire, complete 144V & 12V, 8ft test drive, first charge
46-24-09Battery Box Design
86-28-09Battery box rack fabrication
37-12-09Finishing welding battery rack and other component removal
37-14-09More battery rack, paint battery rack, get engine hoist
1.57-19-09Mount flywheel to motor
37-21-09Tach adaptor design, machine magnet mount
67-23-09Motor prep & input
77-24-09Motor mounting, front battery rack fab
57-26-09Fab last battery rack, "machine" aluminum mounting plate
27-29-09Finish mounting Al plate and try to arrange components
47-30-09Mount conduit, mounting component planning
48-2-09Machine custom parts
18-4-09Test battery fit and parts
18-10-09Pull wire through conduit and stuff
18-11-09Finalize tach adaptor, get more batteries
3.58-14-09Fab PS mount, machine starter cover plate & install
78-15-09Lots of component mounting
1.58-21-09Mounting power steering pump and vacuum switch
68-22-09Wiring various stuff
48-24-09Wiring 12v dist
1.58-25-09Wiring 120 VAC box in gas inlet
19-1-09Start sanding AL plate
29-4-09Begin mounting components to plate
49-6-09Wire & install gage pod
49-7-09Wire & test PS pump, mount gauge pod, attempt diagnose weeee sound
1.59-9-09Finish sanding AL plate
39-10-09Final hookup and test drives
Phase 423 total
29-14-09Attempt to wire second battery remote
49-15-09Wire remotes, redo 2/0 in front, fix temp
29-24-09Sub box design
59-26-09Build sub box, figure out battery leak
39-27-0912V aux battery, balance battery acid levels
69-27-09More box building, wire 12V aux batt
19-28-09Caulk box, apply website tattoos

This website is powered by a custom database driven content management system designed by myself. It is also always under construction. There are probably lots of dead links, maybe I'll have them fixed some day.

The Evan Beloni site has been designed by Evan Beloni for use with desktop browsers Chrome, Mozilla Firebird or Firefox. It may not look good on mobile devices. If there is any praise, problems or patrons, please send an email to . Thanks.
© 2010 Evan Beloni Blacksburg, VA 24060 All php and HTML developed by Evan Beloni.