'63 VW Transporter - EM57 Powered.

[jerrykco]

You might want to take a look at your gearbox before you start getting too far into the build. .

Hi Ian,
I have a newly rebuilt freeway flyer transmission and a new set of higher geared transaxles. So what you see in the picture will be replaced.
Above in previous posts in this thread, I mentioned that I would be reviewing how others mounted their Leaf motor, I was thinking of your project.
I'll be looking it over in great detail and may be asking you some questions if you don't mind.

[ianlighting]

Hi Ian,
I have a newly rebuilt freeway flyer transmission and a new set of higher geared transaxles. So what you see in the picture will be replaced.
Above in previous posts in this thread, I mentioned that I would be reviewing how others mounted their Leaf motor, I was thinking of your project.
I'll be looking it over in great detail and may be asking you some questions if you don't mind.

Sounds good. Happy to answer anything. I should add, I’m not going to be the right person to help on Zombie VCU stuff, and I do consider myself to still be very much a learner on the whole world of EV conversion, but if there’s any insight I can share I’ll be happy to.

[jerrykco]

that sucks, you could possibly harvest the good cells from the module for other purposes. But I would just slowly drain that cell to 0, and do it in an isolated area. Just reduces the chance of anything happening

Yeah, it does. All 32 Modules are currently sitting at 21.7V including the damaged one. I'll isolate it outside and use a big ass ceramic resister to drain it. Once drained I know there is a facility that recycles the lithium batteries in the USA. I'll see if they want it.
https://li-cycle.com/

[jerrykco]

Sounds good. Happy to answer anything. I should add, I’m not going to be the right person to help on Zombie VCU stuff, and I do consider myself to still be very much a learner on the whole world of EV conversion, but if there’s any insight I can share I’ll be happy to.

There is significant difference between your transmission and mine. And also how they are mounted to the frame I see. I've been examining them from yours and my pictures. I also included a pic of the gear reduction axle transmission.
Not insurmountable "problems" yet to be solved. Ha!

[ianlighting]

I’m not surprised there are differences given the 70’s bay window was the next generation on from your split screen type.

In case you’re not familiar, The Samba is a great place to get all the expert VW knowledge if you need it.

[J0hannes]

There is significant difference between your transmission and mine. And also how they are mounted to the frame I see. I've been examining them from yours and my pictures. I also included a pic of the gear reduction axle transmission.
Not insurmountable "problems" yet to be solved. Ha!

It is so cool, that you actually have portal axle gearing on that!
I suppose the gear reduction axle transmission you refer to is the gearbox on the wheel hub?

A benefit is increase in ground clearance under the axle, but downside additional possible failure point and transmission losses.

You may want to open those boxes and see how beefy gears they have in before giving full chooch of the Leaf motor

[jerrykco]

It is so cool, that you actually have portal axle gearing on that!
I suppose the gear reduction axle transmission you refer to is the gearbox on the wheel hub?
A benefit is increase in ground clearance under the axle, but downside additional possible failure point and transmission losses.
You may want to open those boxes and see how beefy gears they have in before giving full chooch of the Leaf motor

Thanks for the link, JOhannes. Very Interesting read. I was told that it was a 1T transporter and the Wiki Confirms that!
"In 1962, a heavy-duty Transporter was introduced as a factory option. It featured a cargo capacity of 1,000 kg (2,205 lb) instead of the previous 750 kg (1,653 lb), smaller but wider 14" roadwheels, and a 1.5 L, 31 kW (42 PS; 42 bhp) DIN engine. This was so successful that only a year later, the 750 kg, 1.2 L Transporter was discontinued. The 1963 model year introduced the 1500 engine – 1,493 cc (91.1 cu in) as standard equipment to the US market at 38 kW (52 PS; 51 bhp) DIN with an 83 mm (3.27 in) bore, 69 mm (2.72 in) stroke, and 7.8:1 compression ratio.
I'll check the gears in the portal axles soon and post pics,

[jerrykco]

I have been working on my CAN_BUS display. This is my Prototype.

I am programming it on a Stone HMI Display I purchased from stoneitech.com in China. I bought it with the stm32 option so I can use the Leaf motor and Orion BMS CAN Messages to update values for the widgit items on the display in real time. I haven't
looked into the Orion BMS Messages yet.

One question is will the Zombiverter have additional CAN Messages I might need and is there a list?

From the Leaf logfile I got from a friend I see:
0X1DA message updates the RPM and HV Battery Voltage.
0x55A message updates the Inverter and Motor Temps.

I am still looking for AMPS [ +/- ]
Help always appreciated.

[T1Terry]

Now for some Pictures:
Rescuing the Transporter:
IMG_5142.jpeg
IMG_5141.jpeg
IMG_5139.jpeg
IMG_5140.jpeg
The Battery
IONIQ 5 Battery.jpg
IQ6-EV Battery label.jpg
IQ6-EV Battery.jpg
The EM57
Left Side EM 57.jpg
Oppisite of Shaft Side EM 57.jpg
Right Side EM 57.jpg
Shaft Side EM 57.jpg

Wow, I've only just stumbled across this build thread and the second post made my eyes water .... an early model Doca they are known as over here, (dual cab ute) I'll get back into the ready now, but I just had to congratulate you on your find .... and having the spirit to turn it into an EV ..... I'm concerned about converting my '74 bay Kombi to electric because they are such nostalgic vehicles, a '63 Doca, that is a whole new world of nostalgic $$ value

T1 Terry

[T1Terry]

There is significant difference between your transmission and mine. And also how they are mounted to the frame I see. I've been examining them from yours and my pictures. I also included a pic of the gear reduction axle transmission.
Not insurmountable "problems" yet to be solved. Ha!

If you are really thinking about using the early reduction hub gearbox, you will need to find a VW transmission specialist who knows these early gearboxes to build it strong enough to handle the torque.

If you go with the floating axle gearbox, count the number of ribs in the gearbox body, you are looking for a 6 rib box or even one of the later boxes, or a special built performance gearbox they use in the open wheeler race cars with the big power motors.

After spreading one of the reduction hub gearboxes across a highway when I bolted a 6 cyl 2850 Holden motor to it, simply accelerating to keep up with traffic, no side stepping the clutch in first gear stuff, I was in 3rd gear at the time, those early gearboxes were about maxed out with the 1500 single carb flat four VW engine.

T1 Terry

[Bratitude]

If you are really thinking about using the early reduction hub gearbox, you will need to find a VW transmission specialist who knows these early gearboxes to build it strong enough to handle the torque.

T1 Terry

Sorta.

in this application there won’t be much of any shifting, or rapid, sharp changes in torque. The shear strength is more of a concern.

the comparing a high hp engine swap on a stock gearbox vs an equal power electric motor dosnt work. How the torque is applied through the drive line is very different.

Also how much throttle ramp is setup. Can make the throttle response very smooth and gradual instead of just dumping everything through the gearbox.

But yes a vanagon 6 rib would be a good bet. But I don’t think that’s an issue in this case.

[jerrykco]

This restoration will not be for racing. I'm thinking of Sunday coffee with the wife, or Ice-cream runs with the grandkids or an EV Show and tell in a park or meet-up.

[T1Terry]

This restoration will not be for racing. I'm thinking of Sunday coffee with the wife, or Ice-cream runs with the grandkids or an EV Show and tell in a park or meet-up.

While you are at this stage of the build, I'd seriously look at either changing the gearbox or doing away with it all together and running the whole leaf motor and gearbox, then you can eliminate having to change gears at all.

There is a lot of room under a Doka rear tray to mount batteries ...... and that was where the load was designed to be carried.
Finding the metal sides that fit on the rear to change it from a flatbed into a ute might be a challenge ..... although, I don't think there are many parts that haven't been recreated somewhere in the world, for every VW model ever made ..... while they were still VW's ..... Brazilian stuff maybe not, they were a real Frankenstein affair .....

T1 Terry

[Bratitude]

While you are at this stage of the build, I'd seriously look at either changing the gearbox or doing away with it all together and running the whole leaf motor and gearbox, then you can eliminate having to change gears at all.



T1 Terry

his stock gearbox is completely fine for the application. KISS, and he has a working doka. Having the multiple gears can be handy when hauling different loads or for city vs hwy.

[jerrykco]

While you are at this stage of the build, I'd seriously look at either changing the gearbox.....
There is a lot of room under a Doka rear tray to mount batteries.....
Finding the metal sides that fit on the rear to change it from a flatbed into a ute might be a challenge .....
T1 Terry

I have a new transmission. Just not a six rib.
The batteries will be going under the rear seat and where the gas tank I removed was.
I have a set of fold down sides and the rear tailgate too.

[jerrykco]

I decided I needed another widget on my display:

[jerrykco]

Regarding the Display I am programming (see post above) that has the ability to receive and filter CAN Messages, I am trying to get a handle on CAN messages I would like to process and display appropriately. I will not have a VCU. Only the ZV + Leaf Inverter-Charger-Motor stack and the Orion BMS.
I have searched the forum for Zombieverter or "CAN Messages" but am unable to find a list of the CAN messages it will produce.
I also looked/searched in the https://openinverter.org/wiki/Special:SpecialPages thinking that would be a good place to look. No Cigar!
If I am using the Zombieverter in a leaf stack without another VCU, is it just the messages from the Leaf Inverter-Charger-Motor stack and if using an Orion BMS the Orion CAN Messages that are the source of the the CAN Messages?

[T1Terry]

I wonder if your display could be used on the Lexus GS450h drive unit and inverter with the Zombi inverter board fitted, and with the Gen 2 Prius and inverter with a Zombi board fitted ..... Hope so, that looks neat .....

T1 Terry

[jerrykco]

I wonder if your display could be used on the Lexus GS450h drive unit and inverter with the Zombi inverter board fitted, and with the Gen 2 Prius and inverter with a Zombi board fitted ..... Hope so, that looks neat .....

T1 Terry

Well with the limited knowledge I have so far, I can't see why any combo with ZV wouldn't work.
The product is simple:
Create the widgets using their graphical user interface (each widget has a unique name
Then filter the can messages you want to act on
If you get a message you want to act on do any calculations you need to update the pointer position for the particular widget.

[T1Terry]

That all looked like a language I should understand I'm sure once I start actually looking at it, it will all become obvious ..... that I can figure it out or I should run for the hills ..... Getting old seems to have that affect I've been noticing lately

T1 Terry

[Bratitude]

Zombie supports obd-ii so any generic gauge interface works.

For example an elm dongle and torq pro gauges on a tablet will display data.
Or real dash, etc
And you can also map to what ever ids you like.

So you can ju

[jerrykco]

Zombie supports obd-ii so any generic gauge interface works.

For example an elm dongle and torq pro gauges on a tablet will display data.
Or real dash, etc
And you can also map to what ever ids you like.

So you can ju

Hey Bratitude, looks like you sent before you finished typing. "So you can ju" ........ I waiting with anticipation.
Also can you look at the I need help understanding message I left here (above) viewtopic.php?p=85587#p85587

[jerrykco]

It's been a while for my updates. But I have been working on the VW on two fronts.
First, I am continuing to strip the Transporter of any attachments albeit slowly. I now have the three doors off. and next I'll be taking all the windows off. After everything is removed I'll build my purchased rotisserie kit to mount it and getting w metal fabricator to help attach it to the VW frame so its balanced in the center so it wont fall over when we start to rotate it to strip it down to the bare metal by media blasting it.
Second, I have continued to learn about how to get the Stone Display to capture the CAN Bus Messages and update the Display Gauges in real time. Today I got it working. Finally! My friend Dan J. helped me debug the last hurdle to get it working. I will be glad to share the code and help anyone trying to do this with the Stone Display. I'll post a video soon.
Today was a huge step forward.