Cliff's '69 VW Karmann Ghia Restoration and Conversion (Electric!)
Front and Rear Views:
Under the trunk Electric logo and back seat batteries:
Console Controls and Console Illuminated!
Console wiring and under the trunk "Electric" logo and carpet added:
Floors Before and After!
Under the Hood and Trunk!
Original Engine and New Electric Motor!
Down to the bare metal!
Interior Before and After!
License Plate Lights:
Size Reference and Air Springs:
LED Controller and New Dash:
1969 Electric Ghia :
Specifications:
Make- Volkswagen
Model- Karmann Ghia
Year- 1969
Color- 2002 Dodge Viper Red
Weight (original)- 1910 Pounds
Weight (converted)- 3000 Pounds (approximate)
Motor- Prestolite MTC-4001 (21HP at 96 Volts)
Controller- Curtis 1221C (72-120 VDC 400 Amps)
Transmission- Standard VW 4-Speed Transaxle
Seating Capacity- 2 Adults
Maximum Speed 65+ MPH (68 really!)
Range- 35 to 50 miles depending on speed and terrain.
Lighting- All LEDs (except headlights)
Heat/Air- Solid State Peltier Junctions (EXPERIMENTAL)
Tire Size- P195/75R14 (inflated to 50 psi)
This car was purchased in May of 2001 through Ebay. It was in a state of serious disrepair, with a lot of rust inside and out. It had the original 50 horsepower gas engine which was removed and replaced with an electric 21 horsepower 96-volt dc motor (equal to approximately 63 horsepower in a gas engine). The floors were cut out and replaced, as were the rocker panels, rear driver’s side lower fender, part of the engine lid skin, lower front fenders, and a strip above the driver’s side headlight. The gas fill lid was removed and filled in. The entire car was taken down to the bare metal. The front axle beam was replaced due to rust and cracks in the lower axle tube. Upper and lower ball joints, tie rods, and ends were replaced with new ones. All CV joints and boots were replaced with new ones. All wheel bearings were replaced and lubed with Slick 50 Teflon grease. The transaxle was removed, flushed, and refilled with Slick 50 Teflon gear lube. All new metal was acid etched and painted with rust proofing paint, as were any areas prone to rust. All of the brake components were replaced with new ones including drums and rotors. Adjustable coil-over shocks were added all around to help with the additional battery weight (approximately 1000 pounds). Air springs were added to the rear suspension to also help with the weight and allow tire clearance. The original seats were removed and replaced with low profile seats to allow for more head and leg room (the owner is 6’5” tall). All rubber components except for the pan gasket were replaced with new parts.
All standard lamps, except headlamps, were removed and replaced with LEDs to lessen current drain on the 12-volt system. Headlights were replaced with halogen lamps instead of the standard sealed beam type. The nose grilles have red, white, and blue LEDs added for show. These scan back and forth with 4 selectable patterns. The turn signals have 6 different patterns that can be changed while driving. The nose grille and turn signal LEDs are controlled with 2 programmable micro controllers and custom driver circuits built by the owner.
A console was added for additional instrumentation and switches, which include 3 LED displays for controller, motor, and heat/air unit temperature. A left and right turn signal LED cluster was added to duplicate the patterns on the outside of the car in order to know that your “blinker” is on and show which of the 6 patterns you’re running. A flashing green LED indicates reverse gear, and a rear-mounted sensor flashes a red LED and beeps a piezo beeper if you’re about to back into something. Interior lighting is also mounted on the console and is accomplished by the use of 6 white LEDs that fade when the doors are closed. A 12-volt Curtis “gas gauge” was added to monitor the 12-volt auxiliary power. 18 console mounted LEDs are used for a VU meter for the left and right stereo channels, as are another 8 on each of the front speakers that light up through the red speaker cones (just for fun). The original fuel gauge was removed and replaced with a Cruising Equipment E-meter to monitor battery condition and power usage. Front and rear cable pulls for the hood and trunk were replaced with solenoid releases.
This car definitely requires a different style of driving, but is quite fun
to drive. Acceleration in first gear is better than the original gas engine. The car can be driven in town like an automatic. You simply leave it in second gear and go. There’s no engine running when you stop, so you don’t have to push in the clutch. Inside you can hear a little drive train noise and road noise due to the stiff suspension and 50 pound of air in the tires to lessen the rolling resistance. Outside the car is practically silent.
If you have questions or comments please feel free to contact me via email at cwiley123@cox.net
Thanks for stopping by!!!
