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Re: Bunky the eBug: A 30 Day EV Conversion

Posted: Tue Apr 14, 2026 3:53 pm
by Gregski
progress not perfection (yet I still used the E6071U welding rod made out of Unicorn dust and a sleeve made out of rare unobtanium)

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using only Internet Approved CV Axles Grease aka IACVAG
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left is in
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and right is in
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and bothties
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Re: Bunky the eBug: A 30 Day EV Conversion

Posted: Wed Apr 15, 2026 2:09 am
by Gregski
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you must mix and match only these two types of gearbox transmission syrup
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Fun Level: 2
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Re: Bunky the eBug: A 30 Day EV Conversion

Posted: Wed Apr 15, 2026 2:32 pm
by Gregski


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Re: Bunky the eBug: A 30 Day EV Conversion

Posted: Thu Apr 16, 2026 3:47 am
by Gregski
next it was time to think outside the sBox, and trying to be symmetrical bit me in the butt right off the bat, can you spot the mistake in the first pic
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a few F bombs later, we made the correction
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I want to say check out these Gregnutz but I better not
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checking for hole alignage
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Re: Bunky the eBug: A 30 Day EV Conversion

Posted: Thu Apr 16, 2026 3:49 am
by Gregski
bracket time, and we keep things simple around these them parts
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and we tried her on for size
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Re: Bunky the eBug: A 30 Day EV Conversion

Posted: Thu Apr 16, 2026 4:08 am
by Gregski
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decided to simplify things and eliminate some of the stock connections
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adding the 15' extension to run back the length of the car through the transmission tunnel
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negative battery to inverter cable
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Re: Bunky the eBug: A 30 Day EV Conversion

Posted: Thu Apr 16, 2026 4:11 am
by Gregski
doing a trial fit to the sBox
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Re: Bunky the eBug: A 30 Day EV Conversion

Posted: Thu Apr 16, 2026 4:14 am
by Gregski
Wait, what? These clips can go on either way ?!

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Re: Bunky the eBug: A 30 Day EV Conversion

Posted: Thu Apr 16, 2026 4:16 am
by Gregski
well I was sort of pot committed, so I went ahead and made the positive battery cable extension as well
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this thing has black wire loom in the middle because that will be hidden in the transmission tunnel and I didn't have enough orange stuff
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Re: Bunky the eBug: A 30 Day EV Conversion

Posted: Thu Apr 16, 2026 4:19 am
by Gregski
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yes the stock positive cable is slightly longer, YES, that will drive me nutz!
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Re: Bunky the eBug: A 30 Day EV Conversion

Posted: Fri Apr 17, 2026 4:02 am
by Gregski
nothing to see here, just fishin' the battery cables through the trans tunnel
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ever wonder what to do with the remaining 10 feet of welding wire when you ran out and the welding machine can't push it through
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not a fan of this high voltage battery cable routing at all, must think on it
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Re: Bunky the eBug: A 30 Day EV Conversion

Posted: Fri Apr 17, 2026 4:06 am
by Gregski
so ended up making another positive cable so that it's the same length as it's negative buddy
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Re: Bunky the eBug: A 30 Day EV Conversion

Posted: Fri Apr 17, 2026 6:22 am
by Ghia66
Knew you would!!! 🙂

Re: Bunky the eBug: A 30 Day EV Conversion

Posted: Fri Apr 17, 2026 8:45 am
by Alibro
I didn't think that would stand the Greg test!

Re: Bunky the eBug: A 30 Day EV Conversion

Posted: Fri Apr 17, 2026 3:38 pm
by Gregski
slightly revised schedule for the purpose of steadfast driveability with some built in padding for nice to have little things like: brakes and seats which I will do off camera on this forum anyway, the Flintstone floors will be delt with later... much later

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Re: Bunky the eBug: A 30 Day EV Conversion

Posted: Fri Apr 17, 2026 10:14 pm
by Alibro
Gregski wrote: ↑Fri Apr 17, 2026 3:38 pm slightly revised schedule for the purpose of steadfast driveability with some built in padding for nice to have little things like: brakes and seats which I will do off camera on this forum anyway, the Flintstone floors will be delt with later... much later


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You don't need to count rot repair in the 30 days. We are kind and helpful that way and are only holding you to the EV conversion.

Re: Bunky the eBug: A 30 Day EV Conversion

Posted: Sat Apr 18, 2026 4:37 am
by Gregski
Alibro wrote: ↑Fri Apr 17, 2026 10:14 pm You don't need to count rot repair in the 30 days. We are kind and helpful that way and are only holding you to the EV conversion.
Bummer !!!

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Re: Bunky the eBug: A 30 Day EV Conversion

Posted: Sat Apr 18, 2026 4:47 am
by Gregski
the pedal SITUATION was next, I had to use an excavator to get the pedal assembly out

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First we had to divorce the clutch pedal, which was easy enuff
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then we had to delete the mechanical skinny pedal
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leaving us with this fugly thing
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nothing a little tickle with the angle grinder couldn't solve
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and normally we would paint it black and put it back, but we was all out of paint
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Re: Bunky the eBug: A 30 Day EV Conversion

Posted: Sat Apr 18, 2026 6:06 am
by Alibro
Are you going to replace the floors or just put extra stiff carpet down?

Re: Bunky the eBug: A 30 Day EV Conversion

Posted: Sat Apr 18, 2026 6:10 am
by Gregski
Alibro wrote: ↑Sat Apr 18, 2026 6:06 am Are you going to replace the floors or just put extra stiff carpet down?

will buy four new quarters and cut them down to what I need once the car drives, the floor pan bolts up to the body so I only need to weld 3 sides of each panel

Re: Bunky the eBug: A 30 Day EV Conversion

Posted: Sat Apr 18, 2026 3:41 pm
by Gregski
next it was time to mountenize the Honda Fit drive by wire hall effect throttle pedal

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so that's the general idea, simple
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Re: Bunky the eBug: A 30 Day EV Conversion

Posted: Sat Apr 18, 2026 4:01 pm
by Gregski
then it was time transfer the shape to metal using my freestyle CNC machines


we only use the finest pieces of scrap metal here at the Good Enuff Garage
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love these hole center pokers
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needed to make one bolt a stud instead for clearance issues
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hold it righty there little buddy
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Re: Bunky the eBug: A 30 Day EV Conversion

Posted: Sat Apr 18, 2026 4:08 pm
by Gregski
tacked into place

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Re: Bunky the eBug: A 30 Day EV Conversion

Posted: Sat Apr 18, 2026 4:15 pm
by Gregski
and bugger welded in, I could not get my big head under that steering wheel with the welding helmet on to see what the hell I was doing, so I welded blind

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looks like folks in the back seat will have no problems reaching this throttle pedal
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Re: Bunky the eBug: A 30 Day EV Conversion

Posted: Sun Apr 19, 2026 9:37 am
by MattsAwesomeStuff
Gregski wrote: ↑Sat Apr 18, 2026 4:47 amthe pedal SITUATION was next, I had to use an excavator to get the pedal assembly out
Okay so it's not just me. I had a hell of a time and eventually just gave up.
I could not get my big head under that steering wheel with the welding helmet on to see what the hell I was doing, so I welded blind
Again, just watching the camera angles I was thinking "How did you even get your head in there?"

I remember when I was trying to reach the pedals, the steering wheel blocked my shoulder, the turning indicator was in my ear, and I could only reach them with the tip of a long screwdriver.

I later took the seat out and still couldn't reach anything worth a damn.

That point where you're panting and struggling and cramping and sore and need a break, and you haven't even done anything other than try to reach where the work should be happening.

...

Congrats on first wheelspin. You hit that without much fanfare. I've taken 5 years to get to that point sometimes. You're barely 5 weeks.