A project for the EV club to ponder

[zepol]

I have purchased a 2003 VW GOLF GL manual to convert to electric. 

Goals:

Have a vehicle with new batteries (not lead acid) capable of 50 miles.  With aged batteries 35miles.  We currently go 30 miles a day in the gas car.

Required top speed of 45, but not necessarily highway capable.

Charge to 35 mile range in 6.5 hours from empty @ home 220Vac charger station.

Engine was 122 ft-lbs, 115hp.  Motor can be much less hp, torque should no be more than 170ish (guess) to be sure the transmission with survive.

Regen power through drive motor

I suspect after engine components, fuel, cooling, and exhaust systems removal it will be near 2300lbs. before electric parts are put in. 

Intent is to mount the motor where the engine was and for now leave the clutch and gearbox intact. 

Links, knowledge, calculations would be appreciated.  Example cars around here?  Online well documented examples, sites that help people with this type of thing?

Topics I am starting with:

Computers

    How to fake out the current computer so everything will still function without an engine.

        Airbags

        Dash controls

    Speed controller

        Matched to motor choice

        Matched to battery Choice

        Capable of regen

    Charging system

        Matched to batteries

        Matched to motor

Motor

    Sizing

    Type

    Mounting

Batteries

    Match to range

    Match to motor

    Match to speed controller

    Charge rate

    Regen power absorption

Mechanicals

    ABS pump

    Brake vacuum assist

    Power steering

    Winter cabin heat?

12V needed

    Headlights

        other lights

    Main computer

    Anti-theft

    Cabin fan

    Radio

    

    My plan is to move this list to a google docs spreadsheet that other can see and edit with me.  I do not plan to post to this group as constant occurrence to avoid "spam"  If you would like to follow my progress or help me directly, please send your email to me directly and I will put you on a mailing list.

    

 

-- Pezz

My privacy is important to me; please do not share information about my family or me without permission.