EV Beetle Conversion Project

 Now I have the awesome adaptor plate I could set about getting the motor in place and start making up a bracket to support it from the engine mount on the drivers side. The passenger side is the gearbox and uses the stock mounting. So this is what I've come up with, with it mounted up I then stood on on top of the motor and gearbox, it was very sturdy. I need to cut it off and give it a paint, and maybe add some more strengthening sections, but I'll do that when it's time for the final assembly. I'll need to bring the charger mounts forward a little, it's fouling the brake servo, I also want to add a little more support for the inverter and charger, but for now my focus is to get the car to move a little under it's own power again. This means wiring in the motor resolver, tracing a couple of wires to my VCU (custom ECU replacement) to use for the CAN BUS to connect the inverter to the VCU for rotor position signals.  I also need to wire in the contactor control

 Very exciting day. If you've followed these posts, you'll see that previously I'd made a very rough plate to mate the gearbox and motor, with limited success due mostly to my lack of accuracy marking and drilling the holes, I no longer need to make use of my ham-fisted attempt. A massive slab of aluminium of 350x300x30mm has become my new adaptor plate, with thanks to someone with the skills and tools to turn the slab in to this thing of bea uty. If you need CAD/CAM/CNC give  Garry @ http://www.gsmachining.co.uk/ a call Can't wait to get this in the car and the mounts made up. With a bit of wiring and some temporary fudges I'd be able to have the wheels turning.

 With the engine removed, there's now a shortage of weight upfront and also space, so I wanted to put the batteries somewhere under the bonnet. The only location available isn't ideal, but then again, you can only work with what you've got. The modules have nice mounting brackets in the case aluminium, so I'd be daft not to use those. I welded up an L shape frame to hang the modules on. I'm quite pleased with how this is coming together now. I still need to come up with some way of protecting them from the weather and road debris. Not be too long now. I may pick up a second pack and mount it in the old fuel tank location if I want more range, but as this is going to be for a local run about, I'm hoping for 25 miles on a good day. That should be plenty for visiting local family and shopping etc. Should be able to replace 80% of my driving with electric.