EV CONVERSION
DRIVE SYSTEM
Gas engine replaced with High Performace Electric Vehicles AC-50 three-phase AC motor
Curtis 1238R-7601 650 Amp Inverter/Controller drives the AC motor
Curtis controller mounted on custom liquid cooled plate designed by HPEVS
Flywheel turned to remove starter teeth and uneeded mass to lighten for a total of 5 lbs.
Custom motor mounting plate plasma cut and angled at M&K Metals in El Segundo
Hub and forged aluminum adapter from East Bay Conversions used to mount EV motor to transaxle
Cooling system radiator, pump and fans purchased from Koolance
Hall effect throttle made by EV West
TRACTION PACK AND CHARGER
Elcon PFC2500 used to charge the battery pack using either 120VAC or 220VAC
Battery racks welded from plans using aviation grade aluminum by Aero Welding in Culver City
Battery pack is 36 CALB SE180AHA LiFePO4 (blue) prismatic lithium iron phosphate cells
Lithium cells are connected in series using braided, high conductivity straps from EVTV
Battery cables and straps are fastened down with Nord-Lock washers
Welding cable 2/0 used for all battery connections
Black ployester strapping used to bind cells into solid modules and to the racks
Ferraz-Shawmut high current semiconductor fast fuses protect the pack in two places
J1772 charging receptacle mounted under the spring-loaded front license holder
Home charging from 120VAC uses adapter and cable with 30 amp switchbox (included)
BATTERY MANAGEMENT
Orion Battery Management System governs the charging and top-balancing of the pack
Orion BMS is servicable using a USB connection and Orion laptop software
Orion sends real-time EV battery pack data using a CAN bus to OBD/Bluetooth transmitter
Samsung 7" Galaxy Tab 2 displays EV gauges by converting the CAN data using the Torque app
MISC
Zivan NG1 DC-to-DC converter supplies the car with 12 volt accessory power
Auxiliary battery module consists of 4 Headway H-38120P lithium cells for emergency power
Ceramic electric thermistor heating element and fan box routed through stock heater flapper boxes
WEIGHT AND RANGE
Original curb weight = 2094 lbs, New curb weight = 2360 lbs (266 lb added)
Front axle curb weight = 1120 lbs, Rear axle curb weight = 1240 lbs
60 miles range on a full charge, depleting no further than 20% SOC
6 Hours required for a full charge from 20% using 220 VAC, and 10 hours using 110 VAC
RESTORATION
INTERIOR
New upholstery complete with firewall pad and new door panels
Complete new carpet kit
Center console and tunnel box storage with padded hinged lid
Luisi custom padded steering wheel with Porsche crest horn button
Custom dash cover (cap)
Original driver door bin and padded armrest lid
Original pasenger door handle and armrest
Upgraded fiberglass speaker housings
Seat belts and winder mechanisms refurbished
ELECTRICAL
Pioneer audio system with input from Galaxy 7" tablet
Window cranks upgraded from mechanical wind to fully electric
Upgraded windshield washer pump and column lever to electric
Complete wiring harness removed, refurbished, and rewrapped
Fuse panel upgraded to JWest Engineering model with blade-type fuses
Running light lenses upgraded to original Euro-style models, front and rear
Headlights upgraded to HID bi-xenon
All windshield wiper rubber seals and bushes replaced with new
Dash knobs all refurbished or new
Fog light housing with amber lens and high intensity LED bulbs
Fog light flash kit installed which activates fog lights with high beam switch
Third brake light custom installed inside rear window
BODY
Body stripped, soda blasted to bare metal, and epoxy primer coated prior to bodywork
Body without rust except for some acid damage in the hellhole area
Windsheild replaced with new XYG glass and seated with original butyl tape
All glass given heat and UV protective tinting treatment
Sidemarker and antenna body holes filled
Three coats of Highway Yellow (52U) applied after bodywork completed
Hood springs upgraded with pnuematic shock kit - front and rear
All rubber seals for doors, trunks, and targa top completely replaced
Underbody thoroghly coated with 3M professional grade undercoat
Trunk interior front and rear compartments floor sealed with 3M undercoat
Interior passenger cabin floorpan sealed with 3M undercoat
All body wells and door interiors coated in POR-15 to prevent rust
Door window mechanisms refurbished and cold galvanized to prevent rust
Targa top stripped and refinished with indescructable textured Line-X bed liner
New stock vinyl applied to sail panels
Heater duct hoses replaced with new
Vitaloni Baby Tornado side mirrors installed
BMW rear view mirror kit installed, mounted on windsheild frame instead of glass
Bumper pad holes weld-filled, and rubber bumper mounting pads replaced
PORSCHE rear grill lettering replaced with new
Special edition Pelican front air dam installed
Rocker scuff panels upgraded to aluminum
All body trim removed, polished and reanodized
MECHANICAL
Steering rack and dust boots replaced
Front ball joints and tie rod ends replaced
Front control arm bushes replaced with Elephant brand rubber parts
Brake calipers all upgraded to PMB Performance gold anodized all around
Brake master cylinder replaced
New metal and rubber brake lines throughout
Rear brake proportioning valve is original and functional
Fuchs reproduction wheels soda-blasted and refinished
Wheel bolts upgraded to permanent studs and acorn cap nuts
Wheel rotors new all around, including bearings and seals
Towbar from Rennen Metal permanently installed under front air dam
Side-shift transaxle rebuilt by Werks II Motorsports in Burbank
CV joints replaced with Auto Atlanta rebuilds on the left side
Shift linkage refitted with new bushings
