Jack Chooses to Revive a Dead Beetle and Make It Green

Should we revive a dead bug to run on gasoline or electricity? Can we afford to go green??? For this project we assume the cost of the body of the 2000 VW beetle is the same for either the gasoline engine replacement or the EV New VW 2000 Gasoline Engine EV Kit#3 conversion kit motor. ii Initial Cost $2,169.50 Kit Initial Cost iii $4,645.00 So we did not include Batteries Initial Cost $2,962.00 the body costs in our Miles per Gallon m/g Average i 24 Miles per KWH (64/30) = m/k 2.13 calculations because they would be the Miles per year estimate m/y 14,600 Miles per year estimate m/y 14,600 same for either Cost per gallon (c/g) $3.60 Cost per kWh (Utah) c/k $0.10 solution. Fuel per year
Fuel per year (c/g)(m/y)/(m/g) $2,190.00 (c/k)(m/y)/(m/k) $684.38

While the initial costs of the EV motor kits Total 5 year life time cost $13,119.50 $11,028.88 are more than three times as much as the gasoline engine kit for the same VW 2000 Beetle, the annual fuel costs are 31% of the cost of gasoline for going the same distance. Over the five year expected life of the cars the EV saves $2,090.63 which may seem modest, but the environmental benefits far outweigh the cost savings the EV may incur. Therefore, we choose to revive the beetle to be all electric, a true EV, with over a 100 mile range per charge. The rest of this report provides the details of these two approaches.
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Year: Make: Model: Item: Option: Available: Average:

2000 Volkswagen Beetle Engine Assembly 2.0L (engine ID AEG) 42

$1,297.50 (SHIPPING included)
View MPG Estimates Shared By Vehicle Owners

2000 Volkswagen New Beetle 4 cyl, 2.0 L, Manual 5spd, Regular Gasolinei

21
City

24
Combined

28
Highway

Supplier: OEM Recycling Networkii __________________________________________________________________________________________

Wilderness E.V. Kit #3 is a 120 volt kit that gives freeway speeds at a lower cost than our Kit #4. Great performance can be had with a 120 volt setup. 120 volts also lets us charge with a normal 110 volt outlet without adding any extra cost. The cost for this complete kit is $4,645.00 + shipping. The complete components for Kit #3 are as follows: * Series Motor 90 HP Peak 6.7" dia. X 15.5" long * Curtis Controller 1231C (144 volts DC at 400 amps) * Adapter Plate for vehicle * Shaft Coupler - Motor to transmission(clutch-less) * 0-5k (pb5)Throttle Box * 40 ft of #2/0 ga. Wire Cable * Contactor- Kilovac EV200 (2000 amp rupture 200 amp continuous) * 50-150 VDC Volt Meter * 0-500 Amp Meter * 50mv - 500 Amp Shunt * Gauge Holder Bracket * 12 - High Current Ring Terminals * 40 - Battery Cable Terminals * Fuse - 400 amp slow blow * Quickcharger 120 VDC (Smart Charger) * 12 vdc Smart Battery Charger (for accessory battery) * General Plans & Wiring Schematics

Installation of the motor is easier than pulling out the original gas motor. In the case of the VW chassis the electric motor is bolted to the transmission with only four bolts. Other vehicles may require more hardware and additional engine mount brackets, but it is still relatively easy compared with the gasoline counterpart. The controller that comes with this 120 volt kit is manufacture by a well-known name in the EV industry. The Curtis 1231C that is included in this kit can be upgraded to 144 volts and will provide great performance. In this picture you can see it mounts easily on the back wall of the engine compartment of the VW Beetle. Because there are so few parts in a EV conversion compared with a gasoline engine, the engine compartment looks relatively clutter free and simple.iii Kit #3 (120 volt system) top speeds will be 60 to 65 mph+ with the range of somewhere between 20 to 60 miles +. Of course many factors can change the performance as mentioned above such as how many batteries you will have in a conversion, etc.iv EV Range Calculatorv Description of battery capacity versus time to discharge and range when used to power a vehicle.vi Cost of Trojan T-105 battery is $148. 10 will give us about 30 miles range while 20 will give us about 64 miles range.vii
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Fuel Economy of 2000 Volkswagen New Beetle, retrieved 3/16/2014 from http://www.fueleconomy.gov/feg/bymodel/2000_Volkswagen_New_Beetle.shtml, U.S. Department of Energy ii 2000 Volkswagen Beetle Used Engines - Specs: 1.9L Manual Transmission, retrieved 3/16/2014 from http://www.autopartsfair.com/volkswagen-used_engines/beetle-2000catalog.html?fit_notes=4ab1a7bfa47e27e18a4ea3111af867f9&seq_num=6, Copyright 2004-2013 Auto Parts Fair. iii Wilderness E.V. Kit #3, retrieved 3/16/2014 from http://www.e-volks.com/kit3.html, Wilderness EV, P.O. Box 50361, Provo, Utah 84605 iv Common Questions and Answers, retrieved 3/16/2014 from http://www.e-volks.com/questions.html. Wilderness EV, P.O. Box 50361, Provo, Utah 84605

EV Calculator, retrieved 3/16/2014 from http://www.evconvert.com/tools/evcalc/, EV Convert.com An in depth analysis of the maths behind Peukert's Equation (Peukert's Law), Retrieved 3/16/2014 from http://www.smartgauge.co.uk/peukert_depth.html Copyright SmartGauge Electronics vii Trojan 6v 225 AH Deep Cycle Golf Cart Wet Battery T-105, retrieved 3/16/2014 from, http://www.batterystuff.com/batteries/golf-cart-products/6-volt-deep-cycle/t-105-6-volt-trojan-golf-cartbatteries.html, Copyright 1997-2014 BatteryStuff.com LLC.
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