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Discussion Starter · #1 ·
Howdy, SpeakEV community!

This is my first post here. I'm converting my trusty VW Passat B4 to EV and wanted to share my progress.

I bought this car a long time ago and quickly fell in love with it. I covered quite some miles with this car and I can safely say that it's a very special vehicle.
This isn't my first EV conversion project, some years ago I converted ZAZ-1103 to electric power. The project was fun, learned a lot while making it.
Another EV conversion project that we did quite some time ago was a Ukrainian Niva conversion, which turned out really great.

Challenges
This time, besides transition to electric power, my goal here is to keep all car systems in working condition. Starting from the power steering, power-assisted brakes, air conditioner and so on...

Why Passat?
You may ask "Why Passat"?
Firstly, everything in this car is really well done. It has a quite advanced configuration for its years. Air conditioner, heated seats, airbags, ABS, it has practically everything you need.
At the same time, this car is quite simple. It doesn't have a central computer, so it'll be relatively easy to make all these systems work.
Of course, there will be some challenges, but nothing too complicated.

Main components
  • Battery pack - 2P26S, 200Ah NMC ~20kWh
  • An asynchronous motor with the copper rotor
  • Curtis 1238 controller 84V 550A
  • Flatpack2 charger
  • BMS A1109 + A11039G2

Progress summary
For someone who wasn't following along on my YouTube channel, I'll quickly sum-up my progress to date:
  • Oct. 9, 2020: Power steering is working
  • Oct. 30, 2020: The motor is installed and working
  • Nov. 13, 2020: Heater and air conditioner installed
  • Apr. 18, 2021: First Test Drive

Plans for the future
So, going forward my plan is to ensure stability and operability of all standard vehicle systems like power steering, power assisted brakes, air conditioning, ABS, etc.
I'll keep you all posted with my progress.

Here's my first test drive video:
P.S. English captions available


let me know what you think.

Thanks!
Yuriy
 

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Impressive piece of work. I have fond memories of a similar TDi engined B4 estate in which I did 80k miles before changing to a B5 estate.
Clearly there is still much to do but it shows the benefit of choosing a car of this age with relatively simple electronics. Why did you choose to keep the gearbox?
 

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Discussion Starter · #3 ·
Impressive piece of work. I have fond memories of a similar TDi engined B4 estate in which I did 80k miles before changing to a B5 estate.
Clearly there is still much to do but it shows the benefit of choosing a car of this age with relatively simple electronics. Why did you choose to keep the gearbox?
I wasn't sure about the required gear ratio, so I kept it to be able to do some experimentation.
 

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Discussion Starter · #4 ·
Hey everyone. Wanted to share my battery experiments progress. Took a road trip today, went to visit my parents. Got encouraging results: 240 km on 40kWh test battery. I was riding at an approximate speed of 70 km/h. A car trailer loaded with a weight of 100 kg takes approximately 25% of the available mileage. Looks like my goal of 320 km on a single charge is not as far away as I expected!
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The location of your "test" battery is good for weight distribution, but a larger battery might not be so good. What are you planning for the rear suspension? Can you get a working set of Boge/Sachs Nivomats for the B4?
 

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Discussion Starter · #6 ·
The location of your "test" battery is good for weight distribution, but a larger battery might not be so good. What are you planning for the rear suspension? Can you get a working set of Boge/Sachs Nivomats for the B4?
I don't think that the rear suspension is overloaded too much.
Considering that there was a gas tank for 70 liters of gasoline + a spare wheel + a muffler, I think, removing all that gave me an additional 100 kg.
A 40 kWh battery will weigh around 170 kg (cells only).
So, in comparison with the original, I now have an overload of only about 70-90 kg.
 

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Ok. I assumed that you were going for a larger capacity battery as you will need 8km/kWh (5m/kWh) to make your target which is impressive for such a big car. Have you done anything to blank out the airflow into the grille which is big enough to cool a big V6?
 

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Discussion Starter · #8 ·
Ok. I assumed that you were going for a larger capacity battery as you will need 8km/kWh (5m/kWh) to make your target which is impressive for such a big car. Have you done anything to blank out the airflow into the grille which is big enough to cool a big V6?
No, I haven't done anything. There's still a radiator of the air conditioner. The airflow goes to cool the electric motor and the controller. Most likely the grille will be partially covered. But I'm not sure yet.
 

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Discussion Starter · #9 ·
Made a little overview of my current DIY battery pack setup.
We'll take a look at how I assembled, installed, and tested it. The battery pack now consists of two battery modules. The first battery module is about 20 kWh and the second one (temporary) is also 20 kWh, which gives me 40 kWh total capacity! You'll see how I assembled and installed the battery from scratch. Also, we'll talk about the battery cells with NMC chemistry that I use, two possible ways of BMS installation and data bus wiring.

 
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