TailgateBattery PackBattery CellBattery Management System RegulatorDC-DC ConverterMotorBattery Pack2Rear motor mountRear bed
OwnerKurt Colvin
Owner's Other EV1980 Commuta Car
LocationSan Luis Obispo, California United States map
Email email image
Vehicle1973 Volkswagen Super Beetle
Started it's life as a regular Super Beetle, but
ended up an EV Utility vehicle.

I got rid of a lot of weight, so the bug is
light and quick.
MotorD&D Motor Systems, Inc. ES-31B Series Wound DC
18HP peak, 12HP continuous:

WebPage /> 31b.htm
DrivetrainFactory 4-speed transaxle.
ControllerKelly KDZ12400
The controller has been software-limited to
use only 300 amps, but it is rated as a 400
amp controller anywhere between 24-120 volts:

WebPage /> p/kdz12400.htm
Batteries32 CALB/Skyenergy CALB-CA100, 3.20 Volt, Lithium Iron Phosphate
The vehicle uses 32 lithium-iron-phosphate
batteries for a system voltage of 102 volts.
The battery pack is managed by the Manzanita
Micro battery management system, which
continuously monitors and balances the cells.
There is a display on the dash that gives data
on all cells all the time, including during
charging. This is a complete BMS solution.

Battery cells: CALB 100 Ah CA Series Lithium
Iron Phosphate Batteries. New in May of 2015,
they
now have 90 cycles on them:

WebPage target="_blank">WebPage /> p?products_id=208

The battery sheet metal boxes and battery
regulators are built by Manzanita Micro:

WebPage target="_blank">WebPage /> page=shop.product_details&flypage=flypage.tpl&
product_id=72&category_id=19

The battery monitoring Dongle Terminator:
WebPage target="_blank">WebPage /> page=shop.browse&category_id=23

System Voltage102 Volts
ChargerManzanita Micro PFC-20
Very flexible and reliable charger:

WebPage
DC/DC ConverterMeanwell SD-350D-12
Reliable DC-DC converter to power all 12V
systems:

WebPage /> DC-DC-Power-Supply-Single-Output-12-Volt-29-
2A-350W-72-144V-9-Pin_2107207.html
Top Speed57 MPH (91 KPH)
I leave it in 2nd gear most of the time, but
go to 3rd gear for freeway speeds. Shifting is
surprisingly easy.

2nd Gear: From a stop to ~35 mph
3rd Gear: 30 mph to 55 mph
AccelerationI've used Kelly Controls' software to limit
the controller to a maximum of 300 amps and to
ramp up at a moderate rate. This is just to go
easy on my battery pack to make it last.
Still, the car pulls away from most at
stoplights. The controller could be set to
accelerate faster.
Range30 Miles (48 Kilometers)
Watt Hours/Mile300 Wh/Mile
I've measured the whr/mile about 10 times. It
all depends on the terrain and speed. The best
I've done is 288 whr/mile and the worst is 413
whr/mile.
EV Miles
Start:2,900 Miles (4,666 Kilometers)
Current:6,198 Miles (9,972 Kilometers)
Total:3,298 Miles (5,306 Kilometers)
 
    As of 5/11/2022
Seating CapacityTwo people up front. A few kids or dogs in the
flatbed.
Curb Weight1,694 Pounds (769 Kilograms)
The empty weight is now just under 1700 lbs. The
car started at just under 2000 lbs from the
factory. I took a lot of weight out by removing
the engine and body.

code by jerry