ICE Breaker - converting a 1967 split to electric drive

Show off your pristine van, restoration, or daily driver.
Post Reply
User avatar
Kevin Sharpe
Registered user
Posts: 311
Joined: Mon Sep 30, 2013 4:12 pm

Re: ICE Breaker - converting a 1967 split to electric drive

Post by Kevin Sharpe »

We've been running some heating/cooling tests on the Tesla battery modules 8)
Battery Rack 1.jpeg
Battery Rack 2.jpeg
Battery Rack 3.jpeg

User avatar
Kevin Sharpe
Registered user
Posts: 311
Joined: Mon Sep 30, 2013 4:12 pm

Re: ICE Breaker - converting a 1967 split to electric drive

Post by Kevin Sharpe »

3D mockup of proposed Tesla module layout for the two battery boxes. One box (8 modules) will be mounted under the floor between the chassis rails, and another (6 modules) above the motor where the petrol tank was located 8)

I had originally planned to build a new chassis that would accommodate all batteries under the floor. However, battery technology is improving so quickly that I decided to shoe horn the batteries in and revisit in a few years when they are half the size/weight.
Battery Packs 3D.png
Last edited by Kevin Sharpe on Thu Dec 21, 2017 12:13 pm, edited 1 time in total.

ted698
SSVC Member
SSVC Member
Posts: 1433
Joined: Mon May 13, 2013 6:12 pm
Location: Bridgnorth, Shropshire.

Re: ICE Breaker - converting a 1967 split to electric drive

Post by ted698 »

Interesting Project - you're certainly putting some work in - keep the updates coming!

User avatar
Kevin Sharpe
Registered user
Posts: 311
Joined: Mon Sep 30, 2013 4:12 pm

Re: ICE Breaker - converting a 1967 split to electric drive

Post by Kevin Sharpe »

ted698 wrote:
Thu Dec 21, 2017 11:51 am
Interesting Project - you're certainly putting some work in - keep the updates coming!
Thanks, it's a fun project :)

sistri
Registered user
Posts: 108
Joined: Thu Sep 12, 2013 4:53 pm

Re: ICE Breaker - converting a 1967 split to electric drive

Post by sistri »

Just picked up on this and its certainly caught my interest, thanks for sharing.

User avatar
Kevin Sharpe
Registered user
Posts: 311
Joined: Mon Sep 30, 2013 4:12 pm

Re: ICE Breaker - converting a 1967 split to electric drive

Post by Kevin Sharpe »

Rapid AC/DC charging connector installed :)
IMG_8872.jpeg
IMG_8873.jpeg

User avatar
Kevin Sharpe
Registered user
Posts: 311
Joined: Mon Sep 30, 2013 4:12 pm

Re: ICE Breaker - converting a 1967 split to electric drive

Post by Kevin Sharpe »

Lots of experiments with the battery boxes and I have decided to reduce the number of Tesla battery modules in the rear to four and save some weight.

In total the twelve Tesla modules will give me 63kWh (P85 modules) or 75kWh (P100 modules) which should be plenty when combined with rapid charging 8)
IMG_8984.JPG
IMG_9005.jpeg

User avatar
Kevin Sharpe
Registered user
Posts: 311
Joined: Mon Sep 30, 2013 4:12 pm

Re: ICE Breaker - converting a 1967 split to electric drive

Post by Kevin Sharpe »

Back of the bus with IRS upgrade... almost ready to install the Tesla drive unit and rear battery box :D
IMG_9033 copy.jpeg

User avatar
susta
SSVC Member
SSVC Member
Posts: 363
Joined: Tue Dec 10, 2013 10:26 pm
Location: sutton

Re: ICE Breaker - converting a 1967 split to electric drive

Post by susta »

I have"nt seen it but have you come across Ian Harris Bay project

User avatar
Kevin Sharpe
Registered user
Posts: 311
Joined: Mon Sep 30, 2013 4:12 pm

Re: ICE Breaker - converting a 1967 split to electric drive

Post by Kevin Sharpe »

susta wrote:
Thu Jan 04, 2018 12:00 pm
I have"nt seen it but have you come across Ian Harris Bay project
I don't think so, do you have any information?

User avatar
Kevin Sharpe
Registered user
Posts: 311
Joined: Mon Sep 30, 2013 4:12 pm

Re: ICE Breaker - converting a 1967 split to electric drive

Post by Kevin Sharpe »

We put the motor back in the bus today and checked clearances ready for the driveshaft fabrication :)
IMG_1925.JPG
IMG_1923.JPG

User avatar
Kevin Sharpe
Registered user
Posts: 311
Joined: Mon Sep 30, 2013 4:12 pm

Re: ICE Breaker - converting a 1967 split to electric drive

Post by Kevin Sharpe »

Porsche wheels 8)
IMG_9055.jpeg
IMG_9056.jpeg

User avatar
susta
SSVC Member
SSVC Member
Posts: 363
Joined: Tue Dec 10, 2013 10:26 pm
Location: sutton

Re: ICE Breaker - converting a 1967 split to electric drive

Post by susta »

Try Brazilian Campers 07845684323

User avatar
Kevin Sharpe
Registered user
Posts: 311
Joined: Mon Sep 30, 2013 4:12 pm

Re: ICE Breaker - converting a 1967 split to electric drive

Post by Kevin Sharpe »

I spent some time reviewing the weight of the Bus conversion today;

The original bus weighed 1036kg (2285lbs).

Removing the ICE, Gearbox, Fuel Tank, and replacing the front/rear suspension with Red 9 resulted in the bus weighing 852kg (1878lbs).

Installing the Tesla Drive Unit, 4 Tesla Battery Modules and rear battery rack resulted in the bus weighing 1046kg (2306lbs).

Now for another 8 Tesla Battery Modules (200kg / 440lbs), 2 Battery Boxes (TBD), and a bunch of electronics (TBD).

While heavy, it looks as if my 1500kg (3300lbs) kerb weight target is achievable (same as a Nissan Leaf), while leaving 570kg (1250lbs) for payload 8)
IMG_3558.JPG
IMG_1921.JPG
IMG_1931.JPG

User avatar
Kevin Sharpe
Registered user
Posts: 311
Joined: Mon Sep 30, 2013 4:12 pm

Re: ICE Breaker - converting a 1967 split to electric drive

Post by Kevin Sharpe »

Carefully removing a redundant tab on the Tesla drive unit allows a bolt on IRS and ~350HP motor upgrade without cutting the bus :cool:

I'll try and record a video next week :)
IMG_9078.jpeg
IMG_9080.jpeg
IMG_9084.jpeg

Post Reply