openinverter forum

Dear experts!

My high respect and many thanks for all the dedication and most valuable information provided by this site!

For 21 years I'm driving a trusty Audi A2 1.2 TDI, up today having accumulated 476.000 kms. Now the engine and its surrounding systems start to show more and more signs of wear, on the other side I still very much like the lightweight, roomy and nicely streamlined concept of this car. So I'm considering to deICE it.

Unfortunately, I did not find any step-by-step manual for a conversion, so I started to dig in more deeply...

My current concept would be:
Tesla Front SDU 112096020g 3d3 induction engine, perferably with aluminum rotor, as I assume it would be lighter. To be mounted replacing the diesel engine, I would design an aluminum support structure connecting the engine to the mounts on the A2 spaceframe.
5 or 6 Tesla Model S battery modules 5.3 or 6.4 kWh, to be installed 1 behind rear axle, 2 to 4 in front of rear axle below rear seat, 1 to 2 in engine compartment.
I consider those items as they seem to be available at reasonable prices. It should give the light car (1245 kg max weight) sufficient power (probably more than this), 25 to 30 kWh capacity would be sufficient for me (I drove for 4 years a Smart ForFour with 17 kWh). Based on the Smart experience quick charging is more important than capacity, so I would like to have 50 kW AC charging, if more can be done easily with DC would be even better... With this concept I hope, German TÜV will not require EMC testing.

Before I start to collect all the necessary stuff (empty A2 spaceframe for studies regarding engine and battery installation, engine, battery modules etc.) may I ask you experts whether this seems a viable concept for a retired aerospace engineer with some experience also in PCB design and microprocessor programming?

Furthermore there are more detailed questions like:
Is the voltage of 5 Tesla battery modules, each having 22 V, wired in series sufficient for achieving a top speed of let's say 130 km/h?
What equipment - if any - would be needed for warming and cooling of the engine and battery modules?

Of course I would make available any design of e. g. engine or battery support structures and present the progress in this thread.

Many thanks for any help,

best regards,

Thomas

Here is what I can provide:

and https://openinverter.org/wiki/Audi_A2_Conversion and https://openinverter.org/shop/index.php ... duct_id=73

Your battery concept won't work for fast charging. You need at least 200V on an empty battery, an empty 5 module Tesla pack is only 100V. CCS chargers don't support such low voltages.

The drive unit will run on the low voltage I assume, just with quite reduced performance, maybe 50 kW

You definitely do not want to use "5 or 6 Tesla modules". You will end up with a very low voltage which will prevent you from getting any performance out of your motor, and will make it harder to find a quality on-board charger and DC-DC converter, and will make it impossible to DC fast charge.

Old tesla modules also tend to be very worn out so you won't get your imagined capacity, and they need watercooling in heavy road trip usage. Plus packaging them is annoying as they are so fragile.

You need to find a battery that will give you your desired capacity while staying in the 200-400V range. A battery pack from a modern PHEV is a good idea. The older ones have less than 10kWh, but newer ones can have almost 20kWh with 96 series cells with is perfect.

The 1.2tdi A2 only has around 60bhp!
The Tesla SDU seems a little over kill - unless you plan on doing some drag racing!
How about the Outlander rear motor? more powerful than your current tdi - and much cheaper than a tesla SDU & very compact.

SuperV8 wrote: ↑Wed Jun 19, 2024 8:34 am The 1.2tdi A2 only has around 60bhp!
The Tesla SDU seems a little over kill - unless you plan on doing some drag racing!
How about the Outlander rear motor? more powerful than your current tdi - and much cheaper than a tesla SDU & very compact.

And it just works with all OEM components via CAN commands from a DIY VCU.