1965 Bug (Electrical Conversion)

The Bug the first day I got it, September 17, 2007. I'm here at the Firestone Brewery in Bulleton, CA.

2009-07-31T13:35:29Z

Frank
The Bug the first day I got it, September 17, 2007. I'm here at the Firestone Brewery in Bulleton, CA.

Another look the first day of the Bug. The Bug ran alright, but it ahd a pretty bad oil leak. No problem in a few weeks the engine would be out.

2009-07-31T14:12:42Z

Frank
Another look the first day of the Bug. The Bug ran alright, but it ahd a pretty bad oil leak. No problem in a few weeks the engine would be out.

My two cars.

2009-07-30T01:31:15Z

Frank
My two cars.

A look at the 1200cc engine. This is the original engine for the Bug. An old 6 volt system still in place. This engine will be out in a few weeks.

2009-07-30T02:22:46Z

Frank
A look at the 1200cc engine. This is the original engine for the Bug. An old 6 volt system still in place. This engine will be out in a few weeks.

The Bug back home safe. Soon everything will change.

2009-07-30T02:26:13Z

Frank
The Bug back home safe. Soon everything will change.

The Bug with little Hobbs the kitten hanging out.

2009-07-30T02:48:45Z

Frank
The Bug with little Hobbs the kitten hanging out.

Front view of the Bug.

2009-07-30T03:09:36Z

Frank
Front view of the Bug.

The seats taken out the Bug looks empty. I'm having the seats totally redone at Mac's Upholstery in Ventura. Once the seats are done I will still leave them out until the rest of the car has ...

2009-07-30T03:11:05Z

Frank
The seats taken out the Bug looks empty. I'm having the seats totally redone at Mac's Upholstery in Ventura. Once the seats are done I will still leave them out until the rest of the car has ...

Looks like shit but some day this will be full of batteries. No back seats, we are shooting for long range. Notice the old 6-volt battery.

2009-07-16T09:03:11Z

Frank
Looks like shit but some day this will be full of batteries. No back seats, we are shooting for long range. Notice the old 6-volt battery.

Another view of the back seats, or where the back seats should be. The back end will hold 5 batteries, while the back seats will hold 7 batteries.

2009-07-30T01:58:50Z

Frank
Another view of the back seats, or where the back seats should be. The back end will hold 5 batteries, while the back seats will hold 7 batteries.

A full view of the back seat area. We will be holding about a half a ton of batteries once everything is set up to run.

2009-01-28T16:14:14Z

Frank
A full view of the back seat area. We will be holding about a half a ton of batteries once everything is set up to run.

Classic early VW steering wheel. I'm keeping most of the Bug original as possible. I will have to add a few gauges to the dash area.

2009-07-30T02:26:39Z

Frank
Classic early VW steering wheel. I'm keeping most of the Bug original as possible. I will have to add a few gauges to the dash area.

The front of the Bug. I will mount the battery charger in the front.

2009-02-08T09:21:30Z

Frank
The front of the Bug. I will mount the battery charger in the front.

There will be no need for a gas tank now, so we removed it. I will put a board with a AVCON charger adapter in here next.

2009-07-30T02:12:15Z

Frank
There will be no need for a gas tank now, so we removed it. I will put a board with a AVCON charger adapter in here next.

The Bug backed up and on Jacks ready for engine removal.

2009-02-08T09:19:16Z

Frank
The Bug backed up and on Jacks ready for engine removal.

The Bug now on jacks, fenders removed, wheels removed, you can see deep inside. Having the fenders removed will help in getting to everything.

2009-02-08T09:20:03Z

Frank
The Bug now on jacks, fenders removed, wheels removed, you can see deep inside. Having the fenders removed will help in getting to everything.

The back view with fenders and wheels removed.

2009-02-08T09:19:44Z

Frank
The back view with fenders and wheels removed.

The nasty, oil-leaking engine. Soon to be removed.

2009-02-08T09:20:39Z

Frank
The nasty, oil-leaking engine. Soon to be removed.

Engine Gone! ony the clutch plate remains.

2009-07-27T14:40:18Z

Frank
Engine Gone! ony the clutch plate remains.

After a little cleaning the engine compartment looks pretty good. I think I removed about a quart of oil and dirt from the compartment.

2009-02-06T07:37:15Z

Frank
After a little cleaning the engine compartment looks pretty good. I think I removed about a quart of oil and dirt from the compartment.

Me removing the oil and crap from the deck lid.

2009-02-06T07:34:31Z

Frank
Me removing the oil and crap from the deck lid.

The 9" GE series motor as it sat when I first saw it . This picture was taken a Thunderstruck motors in Santa Rosa, CA.

2009-02-06T23:26:31Z

Frank
The 9" GE series motor as it sat when I first saw it . This picture was taken a Thunderstruck motors in Santa Rosa, CA.

It might not look like much, but this is a very powerful motor. It needs some work to look good.

2009-02-06T23:26:22Z

Frank
It might not look like much, but this is a very powerful motor. It needs some work to look good.

This is the way I like to work, a beer and a work bench.

2009-02-06T23:25:02Z

Frank
This is the way I like to work, a beer and a work bench.

Now that is how a motor should look. After a week of hard work, scraping and sanding the motor looks almost new.

2009-02-06T07:36:30Z

Frank
Now that is how a motor should look. After a week of hard work, scraping and sanding the motor looks almost new.

Next stage is to mount this motor to the transmission of the Bug. You can see where the motor needs to end up.

2009-02-06T07:36:02Z

Frank
Next stage is to mount this motor to the transmission of the Bug. You can see where the motor needs to end up.

A close up of the name plate on the motor. Not a very good shot.

2009-02-06T07:37:39Z

Frank
A close up of the name plate on the motor. Not a very good shot.

This is a picture of the aluminum plate that will attach the motor to the transmission. Adapter plate kits are sold for bugs, but at the cost of $600.00. We decided to make our own. so with ...

2009-02-05T07:39:26Z

Frank
This is a picture of the aluminum plate that will attach the motor to the transmission. Adapter plate kits are sold for bugs, but at the cost of $600.00. We decided to make our own. so with ...

Coating the plate with blue dye for drill holes. The book that is open is a copy of "Convert It", a very popular book for electrical car conversion. You can buy it for about $25.00.

2009-02-05T07:40:35Z

Frank
Coating the plate with blue dye for drill holes. The book that is open is a copy of "Convert It", a very popular book for electrical car conversion. You can buy it for about $25.00.

Now we are ready to drill the holes. The drill press makes drilling easy.

2009-02-05T07:39:16Z

Frank
Now we are ready to drill the holes. The drill press makes drilling easy.

A close up view of how we made the drill marks. You can see how Justin carefully marked each hole after determining the radius.

2009-02-05T07:41:23Z

Frank
A close up view of how we made the drill marks. You can see how Justin carefully marked each hole after determining the radius.

Some wires that need to be removed. I took this picture so I would know how they go back.

2009-02-05T07:42:23Z

Frank
Some wires that need to be removed. I took this picture so I would know how they go back.

Another wiring picture here. I don't want to forget. That rust in the back ground will be removed and painted soon enough.

2009-02-05T07:38:05Z

Frank
Another wiring picture here. I don't want to forget. That rust in the back ground will be removed and painted soon enough.

Here is a picture of the motor on the left and the VW flywheel on the right. The shaft of the motor must align with the inner diameter of the flywheel.

2009-02-05T07:39:05Z

Frank
Here is a picture of the motor on the left and the VW flywheel on the right. The shaft of the motor must align with the inner diameter of the flywheel.

Here is a picture of the aluminum plate mounted to the motor.

2009-02-05T07:42:06Z

Frank
Here is a picture of the aluminum plate mounted to the motor.

A piece of Stainless steel being machined by Justin. This hunk of steel is used to connect the motor shaft to the flywheel.

2009-02-02T19:40:42Z

Frank
A piece of Stainless steel being machined by Justin. This hunk of steel is used to connect the motor shaft to the flywheel.

Stainless steel is hard to machine, but after many coats of oil things start coming together.

2009-02-02T19:44:27Z

Frank
Stainless steel is hard to machine, but after many coats of oil things start coming together.

You can see Justin working the lathe.

2009-02-02T19:44:23Z

Frank
You can see Justin working the lathe.

Almost done with the inner diameter of the shaft. We recycled the shavings.

2009-02-02T19:41:13Z

Frank
Almost done with the inner diameter of the shaft. We recycled the shavings.

Justin is the man, this project would not be possible if Justin was not involved. Here he is testing the fit of the stainless steel shaft.

2009-02-02T19:43:34Z

Frank
Justin is the man, this project would not be possible if Justin was not involved. Here he is testing the fit of the stainless steel shaft.

A couple more turns and it will be done.

2009-02-02T19:41:49Z

Frank
A couple more turns and it will be done.

Now Justin cuts a big hole in the aluminum plate for the shaft of the motor to go through. We are real close at this point to mounting the motor.

2009-02-02T00:22:42Z

Frank
Now Justin cuts a big hole in the aluminum plate for the shaft of the motor to go through. We are real close at this point to mounting the motor.

Justin finishing off the main hole in the aluminum slab.

2009-02-02T00:17:47Z

Frank
Justin finishing off the main hole in the aluminum slab.

Installed new HEAVY duty shocks on the bug. We had to use a jack to install them. The spring tension on these shocks is so good that after we installed the shocks and lowered down the Bug, t ...

2009-02-02T00:21:48Z

Frank
Installed new HEAVY duty shocks on the bug. We had to use a jack to install them. The spring tension on these shocks is so good that after we installed the shocks and lowered down the Bug, t ...

The Aluminum plate now cut for the internal shaft and mounted.

2009-02-01T19:27:59Z

Frank
The Aluminum plate now cut for the internal shaft and mounted.

The clutch plate and clutch pad mounted to the fly wheel.

2009-02-01T19:31:48Z

Frank
The clutch plate and clutch pad mounted to the fly wheel.

Here is the stainless steel shaft mounted in the vise. The key way has been started. The brass shaft sits waiting shaping. It is all about small cuts with the file to make the key-way slot.

2009-02-01T19:27:57Z

Frank
Here is the stainless steel shaft mounted in the vise. The key way has been started. The brass shaft sits waiting shaping. It is all about small cuts with the file to make the key-way slot.

Making the key-way for the stainless steel hub. Stainless steel is very hard to work with. I spent almost four solid hours filing this hub with a file.

2009-02-01T13:35:04Z

Frank
Making the key-way for the stainless steel hub. Stainless steel is very hard to work with. I spent almost four solid hours filing this hub with a file.

The infamous stainless steel hub. I have been at this thing for a few days now. I must say stainless steel is very hard to work with.

2009-02-01T13:01:55Z

Frank
The infamous stainless steel hub. I have been at this thing for a few days now. I must say stainless steel is very hard to work with.

The hub piece almost complete.

2009-02-01T13:06:06Z

Frank
The hub piece almost complete.

Down the shaft of the stainless steel hub. It may not look like much but that groove has taken many hours of labor to get this thing ready.

2009-02-01T13:05:21Z

Frank
Down the shaft of the stainless steel hub. It may not look like much but that groove has taken many hours of labor to get this thing ready.

An overview of the clutch/flywheel assembly, along with the motor.

2009-02-01T19:28:21Z

Frank
An overview of the clutch/flywheel assembly, along with the motor.

Here is the electric bike, along with the progress made as of 11-12-2007.

2009-02-01T19:28:28Z

Frank
Here is the electric bike, along with the progress made as of 11-12-2007.

Same view as before, just no flash. You can see the motor on the bench top, along with the clutch/flywheel assembly and the stainless steel shaft in the vise.

2009-02-01T19:28:20Z

Frank
Same view as before, just no flash. You can see the motor on the bench top, along with the clutch/flywheel assembly and the stainless steel shaft in the vise.

My seats back from Mac's Upholstery. For $250.00 I had both seats upholstered. I bought the covers Mac's fixed a few broken springs and painted each from. They also put in new Padding.

2009-02-01T10:04:40Z

Frank
My seats back from Mac's Upholstery. For $250.00 I had both seats upholstered. I bought the covers Mac's fixed a few broken springs and painted each from. They also put in new Padding.

Checking the out the seats with my two kiddies Hobbs and Snickers.

2009-02-01T10:07:17Z

Frank
Checking the out the seats with my two kiddies Hobbs and Snickers.

These seats look like new. Mac's does such a nice job.

2009-02-01T10:02:37Z

Frank
These seats look like new. Mac's does such a nice job.

Justin using the Lathe to drill out the brass bushing.

2009-02-01T05:23:00Z

Frank
Justin using the Lathe to drill out the brass bushing.

This brass bushing piece is used to guide the motor to the transmission. This piece of brass was a lot easier to machine than the stainless steel.

2009-02-01T05:21:05Z

Frank
This brass bushing piece is used to guide the motor to the transmission. This piece of brass was a lot easier to machine than the stainless steel.

Trimming down the stainless steel piece to the proper height.

2009-02-01T05:17:59Z

Frank
Trimming down the stainless steel piece to the proper height.

I'm pouring cutting oil on the stailess steel piece. Justin is the background operating the Lathe.

2009-02-01T05:20:45Z

Frank
I'm pouring cutting oil on the stailess steel piece. Justin is the background operating the Lathe.

Cutting the stainless steel piece. More smoke during the operation than any to date. The picture failed to capture how smokie things got.

2009-02-01T05:21:11Z

Frank
Cutting the stainless steel piece. More smoke during the operation than any to date. The picture failed to capture how smokie things got.

Another angle of Justin and myself cutting the stainless steel piece.

2009-02-01T05:22:20Z

Frank
Another angle of Justin and myself cutting the stainless steel piece.

The stainless steel piece having the mounting screws drilled out.

2009-01-29T12:07:40Z

Frank
The stainless steel piece having the mounting screws drilled out.

After a couple weeks of hard work, the Stailness steel piece in its finally form.

2009-01-29T12:08:14Z

Frank
After a couple weeks of hard work, the Stailness steel piece in its finally form.

Trimming down a six inch diameter chunk, 1/8 inch deep.

2009-02-01T05:19:43Z

Frank
Trimming down a six inch diameter chunk, 1/8 inch deep.

Justin using the mill. We found out we needed to make some clearance for part of the flywheel. The inner 5" or so of the flywheel is sticks out further than the rest. This problem was fixed ...

2009-02-01T05:18:36Z

Frank
Justin using the mill. We found out we needed to make some clearance for part of the flywheel. The inner 5" or so of the flywheel is sticks out further than the rest. This problem was fixed ...

Justin working the Mill, this time insetting the Aluminum plate for the flywheel.

2009-01-29T12:07:57Z

Frank
Justin working the Mill, this time insetting the Aluminum plate for the flywheel.

A close up view of the milling process.

2009-01-29T12:09:43Z

Frank
A close up view of the milling process.

Hobbs, helping me on my Bug. He has lots of great advise for me to use. He knows how a VW should sound, Pprrrrrrrrrrrrrrrr.

2009-01-29T12:06:34Z

Frank
Hobbs, helping me on my Bug. He has lots of great advise for me to use. He knows how a VW should sound, Pprrrrrrrrrrrrrrrr.

The Aluminum plate finished and ready to mount to the motor. Most people who convert cars to electric buy and ready made adapter plate. We decide to make our own. This decision has taken mor ...

2009-01-28T22:49:33Z

Frank
The Aluminum plate finished and ready to mount to the motor. Most people who convert cars to electric buy and ready made adapter plate. We decide to make our own. This decision has taken mor ...

The flywheel ready to bolt on the the stainless steel motor shaft.

2009-01-28T22:48:55Z

Frank
The flywheel ready to bolt on the the stainless steel motor shaft.

This is the way we lowered the motor into the Bug. It really didn't take very long to mount once we did it.

2009-01-28T22:49:26Z

Frank
This is the way we lowered the motor into the Bug. It really didn't take very long to mount once we did it.

The motor mounted. The big day 12-06-2007. Next step will be to get batteries.

2009-01-28T22:51:44Z

Frank
The motor mounted. The big day 12-06-2007. Next step will be to get batteries.

A top view of the motor mounted.

2009-01-28T22:51:36Z

Frank
A top view of the motor mounted.

Another view of the motor mounted to the transmission.

2009-01-28T22:51:55Z

Frank
Another view of the motor mounted to the transmission.

Looks different from any VW engine I have ever seen. This 9" motor will provide enough power to push this bug 75MPH.

2009-01-28T22:48:21Z

Frank
Looks different from any VW engine I have ever seen. This 9" motor will provide enough power to push this bug 75MPH.

A view from the bottom looking up at the mounted motor.

2009-01-28T22:51:07Z

Frank
A view from the bottom looking up at the mounted motor.

This thing is the main contactor. This device runs off of 12 Volt DC and closes the 144DC circuit. We will remove this item from the this plastic backing and place it in the Bug.

2009-01-13T02:13:26Z

Frank
This thing is the main contactor. This device runs off of 12 Volt DC and closes the 144DC circuit. We will remove this item from the this plastic backing and place it in the Bug.

A side view of the main contactor switch. I got this used from Thunderstruck motors.

2009-01-13T02:12:32Z

Frank
A side view of the main contactor switch. I got this used from Thunderstruck motors.

Another look at the Bug as it sat in the driveway for almost 5 months. You can see little Hobbs snooping around.

2009-01-13T02:16:47Z

Frank
Another look at the Bug as it sat in the driveway for almost 5 months. You can see little Hobbs snooping around.

This is the raw materials (3/4" plywood), needed to make the battery boxes.

2009-01-13T02:11:35Z

Frank
This is the raw materials (3/4" plywood), needed to make the battery boxes.

We took the back seats out inorder to make room for the large amount of batteries that we will need. A 3/4" piece of plywood was stuck in place of the seats. This will provide us the strengt ...

2009-01-13T02:13:04Z

Frank
We took the back seats out inorder to make room for the large amount of batteries that we will need. A 3/4" piece of plywood was stuck in place of the seats. This will provide us the strengt ...

Another look at the 3/4" plywood base from which the batteries will sit. No back seats in this Bug.

2009-01-13T02:14:40Z

Frank
Another look at the 3/4" plywood base from which the batteries will sit. No back seats in this Bug.

Here is Justin crafting the battery boxes. We had to take apart the box Justin is working on in the picture because it wouldn't fit into the Bug whole. We were forced to take the box apart a ...

2009-01-13T02:16:30Z

Frank
Here is Justin crafting the battery boxes. We had to take apart the box Justin is working on in the picture because it wouldn't fit into the Bug whole. We were forced to take the box apart a ...

A view of the front battery box as it was being installed.

2009-01-13T02:15:29Z

Frank
A view of the front battery box as it was being installed.

Another view of the installation of the front battery box being installed.

2009-01-13T02:14:20Z

Frank
Another view of the installation of the front battery box being installed.

Many wood screws were used to ensure the boxes could hold all the weight. Glue was also used to hold everything together.

2009-01-13T02:12:29Z

Frank
Many wood screws were used to ensure the boxes could hold all the weight. Glue was also used to hold everything together.

looking through the side window at Justin building the back battery box.

2009-01-13T02:14:03Z

Frank
looking through the side window at Justin building the back battery box.

This is the metal strap the will hold the battery boxes from sliding forward and killing the driver if an acident should occur. Justin is here welding the strap.

2009-01-13T02:12:52Z

Frank
This is the metal strap the will hold the battery boxes from sliding forward and killing the driver if an acident should occur. Justin is here welding the strap.

Another look at Justin welding the strap.

2009-01-13T02:16:01Z

Frank
Another look at Justin welding the strap.

The strap almost complete here.

2009-01-13T02:14:34Z

Frank
The strap almost complete here.

Battery boxes installed and the batteries put into place. We are using twelve, 12 volt 110 amp-hour batteries. We bought AGM, valve regulated batteries. These batteries require no maintenanc ...

2009-01-13T02:16:14Z

Frank
Battery boxes installed and the batteries put into place. We are using twelve, 12 volt 110 amp-hour batteries. We bought AGM, valve regulated batteries. These batteries require no maintenanc ...

Another look at the batteries in the battery boxes. The strap is used to place the last battery in place without dropping it in. The strap also helps pull the first battery out if needed.

2009-01-13T02:16:03Z

Frank
Another look at the batteries in the battery boxes. The strap is used to place the last battery in place without dropping it in. The strap also helps pull the first battery out if needed.

Here is a look at the wiring progress as it was happening. At this point we were just hours away from a test drive.

2009-01-13T02:15:50Z

Frank
Here is a look at the wiring progress as it was happening. At this point we were just hours away from a test drive.

This how the battery boxes look when covered. You can hardly tell that this Bug is electric.

2009-01-13T02:13:48Z

Frank
This how the battery boxes look when covered. You can hardly tell that this Bug is electric.

Another look at the battery boxes with lids installed. You can see the saftey metal strap on both battery boxes.

2009-01-13T02:14:06Z

Frank
Another look at the battery boxes with lids installed. You can see the saftey metal strap on both battery boxes.

The back of the Bug. No more back seats, batteries contained under the covers.

2009-01-12T02:22:58Z

Frank
The back of the Bug. No more back seats, batteries contained under the covers.

Justin using the crimper for the lugs. This crimper is used by Southern California Edison. Our neighbor works for SCE and was able to get us the lugs and the crimper. The lugs are very expen ...

2009-01-13T02:15:28Z

Frank
Justin using the crimper for the lugs. This crimper is used by Southern California Edison. Our neighbor works for SCE and was able to get us the lugs and the crimper. The lugs are very expen ...

Here is what the engine compartment looks like now. From the bottom you can see the motor (9", GE, Series wound motor). Straight up from the motor is the Curtis 500 Amp controller. To the le ...

2009-01-13T02:15:13Z

Frank
Here is what the engine compartment looks like now. From the bottom you can see the motor (9", GE, Series wound motor). Straight up from the motor is the Curtis 500 Amp controller. To the le ...