356 Porsche Speedster Electric Car Build - EVoutpost

so around 2010 we started seeing the the Tesla Roadster height and if you look at it just based on specifications you're like this power plan we should be able to put this in other cars we just kind of started a project kind of like a technical exercise to see if we could actually build our own you know kind of homebrew electric race car [Music] [Applause] [Music] [Applause] [Music] [Applause] [Music] hi there I'm Jehu Garcia your hosts usually I'm a YouTube vlogger that explores electric cars and battery technology that's why I'm here today at EVs I want to show you how they convert a classic car into an electric vehicle let's go hey Michael what's up man good to see you yeah is this a new project yeah this is what I was telling you about 1957 Porsche speedster it's a replica made by vintage speedsters in Hawaiian Gardens really nice and lightweight these fiberglass ones they use the Volkswagen pan so all of our fitment parts are gonna go right into it we're gonna use the brand new Tesla Model S battery so we're gonna get you know over 100 miles range out of this car but still keep it really lightweight we only have about a 260-pound battery in this very light and we're putting a brand new motor in it brand new motor out of Germany it's a synchronous reluctance internal permanent magnet motor well no that's a mouthful but it's a high-efficiency motor and it's the brand-new technology basically it has tons of torque we're gonna have about 175 foot-pounds at the rear wheel Wow it's gonna be fun to drive again it's gonna be worthy of its name a Porsche speedster it's gonna be yeah it's there alright who's doing this one Trent's gonna do this one for us yeah he's our most experienced technician and we expect a real clean one all right let's get them on him let's do it hi my name is Trent and I am the lead technician at Evo s I'll be doing the conversion on this year 1957 replicas feature [Music] oh man well we have a replica speedster in our shop probably one of the first fiberglass cars have done but pretty good quality from what I've seen underneath usually the first step in a conversion is to remove the old gasoline engine but this project here is what it's known as a roller it's basically a car that is sold to the customer without a motor so the next step is engineering Trent what do we have to engineer for this car when it comes to engineering on one of these cars you need to do a lot of initial measuring and a lot of times that determines what type of battery or what configuration of battery that you use because if you're gonna try and fit say like a Model S battery in one of these cars a lot of times it just won't fit because of the form factor so that's a big consideration especially a small car like this which is 11 in shorter wheelbase than a Volkswagen Beetle choosing the right batteries for these projects is very important some are small and light but very powerful which are great for high-performance vehicles while others can store a lot of energy and are great for daily drivers this particular build is going to be a bit of both quick and light but it's also going to have a hundred miles of range as its using battery modules that came off a Tesla Model S car before I do any placement in the car I try and mock up everything in 3d on the computer and a CAD program and that helps me to get most of the dimensions figured out and know exactly how much distance I have between say the front of the batteries and the back of the motor and actually put that into a real time dimension in the car I'm lucky in this scenario because now we have a lot of parts off-the-shelf that we use in a lot of these conversions such as our adapter plate for the Volkswagens they're all billet and it just makes my life so much easier I can grab something off the shelf bolted up and I can have a motor in the car in under an hour so let's install the front battery box [Music] one of the challenges with this car is that we're putting a lot of new technology and each of these and these battery boxes in particular they're getting a battery management system which takes up a little bit more real estate as well as maintenance and safety switches inside the battery boxes as well what's here again that's more cabling it's just more components inside and so that means you need to be more diligent about assembling this battery box in 3d so you don't get all your batteries stuffed in it spend a bunch of money on fabrication in the actual box and not be able to fit anything after that we've got our front box in today with a little modification to our bracket tree underneath but in the end it was a nice snug fit and we didn't have to cut any more fibreglass when we intended to in the beginning looks like we're gonna burn the midnight oil [Music] [Music] [Applause] [Music] all right day two we start with the huddle in the dirt yeah all the same guys do it because you can valve it instead of okay now let's do some work in the back battery box area so for instance in this car we're putting an entire battery box behind the firewall because we wanted to retain the rear seat so we had to get creative we're putting batteries in this car usually the battery boxes are the most engineering intensive part of the dil okay I think we're ready to go in cross your fingers being the biggest and heaviest part of the conversion securing battery boxes to the cars frame marks a major milestone on these type of projects [Music] okay I think it's time to put the motor in in all this car is getting a few new components that I haven't installed yet this will be my first time installing the SME motor the synchronous reluctance motor that we really like good-looking as well as good power so first up we're gonna put our bell housing adaptor onto our electric motor this is a custom-made piece of aluminum that adapts the electric motor to the original transmission this will take a look taking a minute to do but it's all necessary next our coupler goes onto the shaft we put this on the hot plate to expand the steel so it slips onto the shaft easier try and get it fortunately this is a little bit of anti-seize just in case the coupler ever needs to come off makes a little bit easier on them our quarter inch key goes into the key way alright now we're ready for our coupler nice and hot before installing the custom-made aluminum flywheel a guide bearing has to be pressed in a little setter bearing in the flywheel just keeps the input shaft from wobbling inside the belt house so next to go on as our flywheel and because this is a tolerance pit I'm gonna heat it up as well [Music] [Music] so what I'm doing here is just getting any oil in the actual clutch friction surface off for the whole assembly goes together or clutch just goes on with the aid of our little clutch alignment tool here next step after the clutch is our pressure plate each click means the bolt has reached the predetermined torque setting number six we're ready to mate to our transmission it's always a good idea to check on the bench for any coupling issues as it could save a lot of trouble later [Music] with everything working as it should it's time to install everything on the car [Music] so since we don't have a starter motor anymore or rather we're just attaching a big starter motor we use these little guys starter block up all right so Wednesday night I still have a few components to put in some of the biggies of the charger charge port contactor box a bunch of cabling so we ultimately have about two to two-and-a-half days left to wire this entire car so it will be tight but ultimately we get it done [Music] I'll definitely be calling to know a good buddy saw [Music] alright so at the end of the day of today we got our two battery boxes in the transmission the motor and controller on top which is a really good haul for one day now five o'clock is hit I think it's time to do good at frosty [Music] right let's do that I think they're outside remember last year there was an Eevee company bankruptcy and we were able to group by one whole pallet of brand-new in factory packaging made in Korea LG 18 650 sells well this year we got 10 pallets so this deal is pretty similar to last year's and that a very popular Eevee company when bankrupt luckily EVs was able to secure such large inventory of some of the best 18 650 s you can currently buy more than a hundred and fifty thousand of Panasonic 18 650 BDS rated at 3200 million powers and BTC sixes rated at 3000 milliamp hours with a 15 amp continuous rating [Music] the past few days the Evie West team has been working to convert this 1957 Porsche speedster into a fully electric vehicle and today is the deadline uce vos has been invited to participate in this year's Encinitas Christmas parade and the team is determined to have the speedster be part of it can they finish it on time so currently we have bare minimum throttle pedal some cabling and of course you need to check in mechanical stuff like brakes make sure they work ok cabling is probably gonna take the most time so that are getting jamming on that for safety all the high voltage wiring is this high visibility orange color in all this car is getting a few new components that I haven't installed yet this will be my first time installing new charger we haven't dealt with yet called a thunderstruck charger and here again a little bit smaller form factor for the same power as we typically use in one of these Chargers they're just air-cooled chargers but if you can get them smaller and lighter than that means you're more efficient [Music] [Applause] [Music] all right so where we're at with a couple hours to go is we've got two OTT cable to run still which are the main power leads we need to wire / throttle and then I think we're ready to fire it off and see car round so that would be the first startup probably less than an hour before we need to be there so kind of close luckily these guys are used to working under tight deadlines yeah becoming a use throttle pedal for these projects this is quite fit on this car so time to find another one sometimes you just need a part that doesn't exist yet so you just printed another component we're putting in this car we haven't done yet is a battery management system and that monitors all your cells to make sure you're never at a dangerous state of charge or basically just keeps your batteries safe which is a big deal because that's a large portion of the cost of these conversions oh we're repurposing Tesla BMS boards as our own ooh oh so you're using the Tesla module so you gotta use the connectors too right yeah cuz these connectors aren't commercially available at this point all the essential high power connections get made they require special attention and concentration as these orange cables carry levels of power equivalent to those required to run a commercial size building at those levels of power any loose or dirty connection can be the cause of extra resistance which in turn causes high levels of heat so no cutting corners in this step this hydraulic crimp tool allows for consistency across all the connections another thing we're installing that kind of enhances the ease of ownership is something called an EVC see it's a electric vehicle charge controller and that monitors what your car is doing in the charging State charging at the top at the bottom and will put you in a limp mode if you're at a dangerous state of charge so it's a little bit more like a VCU it gives your car a little bit of added safety factor a little bit more brains yeah that's a good way of putting it with the start of the Christmas parade nearing the rest of the guys in the shop decide to lend the hand how did you want the need to run the cables here underneath the carpeting Oh 35 [Music] so I should be there so I'm gonna take off but you know the parade starts at 5:30 but by the time that spot baby moves it's like 6:00 a57 6:30 that's like an hour all right well despite all the good help we got from the guys in the shop here we're not gonna make the show and that's okay we're still gonna go and support all of our customers that have cars in it we were just a few components away and stuff that you don't want to cut corners on like throttle pedal and 12-volt system is necessitated to get running so just a few things held us back but come in Monday and bang it out [Music] [Music] so we didn't get the Porsche done in time for the Christmas parade but we took six other cars down there and the city of Encinitas like a lot of cities really embraces the electric cars so they gave us six spots in the parade to kind of show off our work and we really would have liked to have the Porsche down there but it just wasn't in the cards this time so yeah we wound up not making it which is kind of a bummer because it was nice to meet your goals but in the end I think you know we kind of went on the side of safety so the next step with the car would be after the parade to just have a little bit of time work on the aesthetics finish up you know we're gonna do a carpet kit up front and some of the other little detail work what's happening here right the adjusters on the spring plates are basically they don't have adjustment so we have to wreak locked the rear arm so we can get more height out of it to clear the wheels gonna fire it up for the first time oh yeah there we go check all of our switches all right so okay first try so then after that point we just need to finish programming and that's about a week or two and at that point we can go ahead and start doing the long-range testing to make sure we know exactly how many miles the car is gonna be able to go Wow well I think it's time for road tests rage testing for us is basically we drive it around in everyday scenarios so it means really that you have to go and sit in traffic go on the highway open it up and really try and get something to break if it can and just make sure that you're not gonna get stranded anywhere I mean that's really important we look for actual usable miles right this isn't we're not hypermiling we're not sitting behind the semi-truck or something on the freeway just to say we can get 200 miles out of the car this is like a real actual usable number one of my favorite routes is right by the beach and you can go up and down the 101 and that way you are sitting in the stop-and-go traffic so where something's gonna heat up it'll do it there and then you can also there's stretches where you can open it up a bit and just make sure that everything is fine under load because that's important [Music] so you know we get asked that like what's the importance of all this so much and I think here it our shop anyways we just want to show that it can be done you know the best way to lead is by example and if we can do this stuff and you know convert these cars in a couple weeks and make the process easier especially with some new parts that we're coming out with it will really make it easy for your just normal weekend shade-tree mechanic to convert a car and I think that's ultimately the goal and while we're on our way to achieving that goal we're converting cars along the way so I'm an optimist I'd like to think that the future is bright and that's the reason why I like electric cars why electric cars I still haven't found anything that can put out like 200 foot pounds and there's a little teeny tiny box you know and and for us its performance in drivability like we everybody here is just really in the driving classic cars and that's you know the environmental benefits are amazing and that's not lost on us but if you lead with that you don't get people as excited is kind of leading with you know performance everybody loves a faster car the side effect of that is you have a sustainable car you can charge it on solar and essentially drive it around and it's not polluting and there's absolutely nothing wrong with that [Music] you [Music] is that full throttle is there drag race here's the GT against my DIY monstrosity that I built ready set go

Channel: jehugarcia

Views: 876,469

Rating: 4.8789587 out of 5

Keywords: lumix, elon musk, gigafactory, tesla model 3, 2170, car, mods, diy car, diy, li-ion, lithium, battery, tesla, swap, tesla battery, powerwall, volkswagen, carros, samba, van, solar, 18650, dead battery, TESLA, motors, ev, electric, electric car, 356 speedster, porsche, electric porsche, can conversion, evwest

Id: 7zOeBYIeAkg

Length: 23min 59sec (1439 seconds)

Published: Tue Dec 18 2018