Retired Engineer’s Thrilling Journey: Reviving a Classic Porsche with Model S Power

Retired Engineer Revs Up Classic Porsche with Model S Power

 In 1960, a young Steve Rose celebrated his 8th birthday. His father had just finished jazzing up a red CJ5 Jeep with a V-8 engine, but all Steve and his brother could think about was taking it for a spin. Finally, fed up with their nagging, Steve’s dad came up with a genius idea: Why not give the boys a car to build?

Building an electric vehicle is not for the faint of heart. It’s more like a full-contact sport!

And so, they purchased a 1954 VW rolling chassis complete with an engine, transmission, seats, and suspension, plus a bonus upgrade to 36 horsepower. With the help of a friend, they welded and painted the rail cage a vibrant orange and white, added some flashy chrome accents, and voila! Finally, the boys had a beautiful sandrail to call their own.

Family Affair

It wasn’t Steve’s first rodeo with cars, either. He’d previously pieced together his own Corvair from parts scavenged from three different junkyards. And with a father who was a sports car enthusiast who owned a 1960 black Corvette, an E-type Jaguar, three different Datsun/Nissan Z cars, and a 1995 red Acura NSX, it’s safe to say that cars were always a big part of his life growing up.

A few years later, Steve decided to up the ante and purchased a Chenoweth bare frame, which he built from the ground up. The engine? A 40-horsepower VW that kicked off a horsepower war.

Not one to back down from a challenge, Steve’s next project was a sandrail with a Hi Jumper chassis and a Chevy V-6 Corsica engine with aluminum heads and multiport fuel injection—one of the first of its kind.

People thought he was crazy, but hey, he’s always had a bit of a wild side. His next creation, a hot rails two-seater mid-engine sandrail with an Acura 3.7L V-6 engine, was a wheelie king!

Building cars and experimenting with different engines are in Steve’s family DNA, a fact that’s been solidified over the years.

EV Revolution

As regulations tightened, swapping engines in street cars became more and more of a hassle. But then came the electric vehicle conversion movement, and Steve was all in. Living in Nevada with his wife, he faced no restrictions on what he could do with his builds.

“You can add a motor to each wheel, use Tesla Lithium-ion batteries, and cram as many cells as you can fit into a car for crazy torque and speed,” Steve says. “Plus, with gas prices sky-high, it’s pretty awesome to not have to stop at the gas station and just charge at home for a fraction of the cost.”

So, last year, Steve couldn’t resist the urge to build again, and the VW Bug, ahem, bug bit him. He reached out to EV West and ordered “the works” to build himself a ride inspired by the shop’s VW and buggy builds.

But then, while browsing the internet, Steve stumbled upon a 2000 black Porsche Boxster for sale, partially converted and priced at just $7,600. With a background in electronics and having recently installed a four-post lift in his garage, he knew this was the project for him.

The conversion runs on a Warp 11 motor paired with the Porsche transaxle, a Zilla Controller, six Tesla modules, and a Thunderstruck Dilithium BMS. Though a bit old-school, the setup works perfectly fine. We hit the road with Steve in Boulder City, Nevada, and let me tell you that’s it’s a joy to drive. With Porsche’s fantastic chassis and suspension, it’s quick and lots of fun.

Thrilling Journey

Steve took on the challenge of building his very own Porsche Boxster EV conversion, and it was a thrilling journey, to say the least. The wiring process was a cakewalk, but the battery management systems presented some problems. Thanks to the support from Thunderstruck and EV West, Steve was able to overcome these challenges and complete the project for just $22,000—including the base Boxster!

Steve took on the challenge of building his very own Porsche Boxster EV conversion, and it was a thrilling journey, to say the least.

One piece of advice from Steve: Don’t take shortcuts! Do your research, take notes, label your wires, and always use safety precautions. He even invested in a wire wrap labeler for a professional touch and suggests measuring voltages twice before terminating wires. And remember, he says, to use insulated tools and gloves and never lay tools on top of the battery packs! To avoid any nasty surprises, Steve also recommends using a small 22- to 24-gauge wire hooked up to the high-voltage connector before touching it to the terminal. It’s like a safety fuse, so if something goes wrong, the wire will melt instead of you!

All in all, Steve’s Porsche Boxster EV conversion is a fun and speedy ride, thanks to Porsche’s fantastic chassis and suspension setup.

So, Steve discovered that building an electric vehicle is not for the faint of heart. It’s more like a full-contact sport. But, if you’re up for the challenge, he suggests getting a complete kit from a trusted company to simplify the process and save some dough. And, if you’re looking for a smoother ride, he suggests opting for an AC inductive motor as it allows for regenerative braking.

Now, with all that being said, Steve’s already on the hunt for his next EV conquest. Are you brave enough to join the electric revolution?

SPECS

Owner

• Steven G. Rose
• Boulder City, Nevada
• Model: 2000 Porsche Boxster 986
• Vehicle Name: PIT
• Vehicle Weight: 2,750 pounds
• Amount of Time to Build: Six months
• Cost to Build: $22,000
• Occupation: Retired, formally project engineer for Johnson Controls

Motor and Drivetrain

• Motor Swap: DIY
• Motor Drive Unit: Netgain Warp 11
• Power: 31.8 Kw (43 hp)
• Voltage: 150 v
• Max RPM: 5,000
• Peak Power RPM: 3,000
• Motor and Transmission Mounts: Original Porsche 5-speed
• Control System and Software: Manzanita Micro Zilla 1k DC series
• Vehicle Weight: 2,750 pounds

Battery System and Amp Charger

• Pack Design: Tesla Model S
• Cell Type: Six cells per pack
• Module Manufacturer: Tesla
• Battery Capacity: 31.8 kWh
• Battery Locations: Four models in the frunk and two in the trunk
• Highway Range: 100 miles
• Regen Type: None
• Charger Charge Rate: 20 amps Thunderstruck EV 2500 programmable Can Bus
• Charger Controller: EVCC V3.0
• Charger Location: Frunk
• Chassis/Suspension
• Rear Suspension Setup: Stock
• Control Arms: Stock
• Spindles: Stock
• Springs: Stock

Wheels, Tires, and Brakes

• Tires: BF Goodrich 205/50ZR17
• Brakes: Stock discs

Body/Paint

• Paint Shop: Original paint
• Color: Factory Black

Interior

• Gauges: TBS Expert Pro battery monitor for lithium packs
• Radio Head Unit: After Market LCD flip touchscreen
• Sponsors: EV West, Thunderstruck, EV4U and Gruber Motors

FREQUENTLY ASKED QUESTIONS

What is included in the complete EV conversion kit for air-cooled Porsche models?

Transform your classic Porsche 911, 912, or 914 into an electric vehicle with our comprehensive EV conversion kit. We’ve streamlined the process by offering pre-assembled, programmed, and tested components to minimize labor and maximize ease.

Standard Kit Components:

• EV HypE™ Drive System: This robust, low voltage 90 kW system, capped at 130 VDC, provides 220 Nm of torque. It comes fully assembled with a DC-DC inverter, a main fuse, control electronics, and a simplified charge controller. It’s designed to be “ready to drive” and complies with EU automotive R100 regulations.
• Throttle Controller: Equipped with a Curtis PB-6 Potbox for smooth throttle response.
• Gearbox Adaptation Kit: Includes an adapter piece, adapter shaft, and rear engine support specifically for mounting the electric motor onto the existing Porsche gearbox.

Optional Battery Pack & Charging System:

• Lithium Battery Options: Choose from various Lithium battery systems, all featuring an R10 approved Battery Management System (BMS) with a connection circuit board and Bluetooth app capabilities.
• Charging Solutions: Offers an OEM-controlled 3.3 kW charger or a 10 kW, 3-phase charging solution, complete with a connection kit and pre-assembled cables measuring 3 meters.
• Charging Socket: Vehicle-side Type 2 “Mennekes” charging socket included for convenient charging.
• Service Disconnect and Cables: Features an HV service disconnect with interlock, along with an 8-meter shielded HV cable following European R100 guidelines, plus additional cables and lugs.
• Buttons and Plugs: Includes all necessary buttons and plugs to complete your electric conversion seamlessly.

This conversion kit offers everything needed for a full transition to electric power and ensures your classic car remains at the forefront of innovation and sustainability.

What is the voltage and power capacity of the EV conversion kit for Porsche models?

The EV conversion kit specifically designed for the classic air-cooled Porsche models, such as the 911, 912, or 914, offers a power capacity of up to 90 kilowatts. It operates with a voltage of 130 VDC, ensuring a robust performance for your vintage vehicle’s transformation into an electric powerhouse.

What other types of vehicles have compatible EV conversion kits available?

EV Conversion Kits for Various Vehicles

If you’re considering transitioning your classic or compact car to electric, there are several EV conversion kits tailored to different vehicle types. Here’s a look at the options available:

• Classic Sports Cars: There are kits designed for vehicles like vintage sports models, offering high-voltage systems that can reach up to 90 kWatts with a 180 VDC configuration. These kits provide a robust solution for those who want to modernize their driving experience while preserving the car’s classic appeal.
• Compact and City Cars: For those owning smaller vehicles, such as compact urban models, low-voltage conversion kits are available. These systems also reach a maximum of 90 kWatts but operate on a 130 VDC setup, ideal for maintaining efficiency and performance within the city.
• Vintage Sedans: If you own a vintage sedan, conversion kits offer compatibility with a similar low-voltage, 130 VDC system, ensuring your car delivers a smooth and eco-friendly ride without compromising its original charm.

Each kit is crafted to enhance your vehicle’s efficiency while being easy to integrate, available in multiple configurations to suit various performance needs and budgets. Whether it’s for a classic car weekend drive or a nimble city commute, these EV conversion kits make electric driving accessible for various automotive styles.

What are the available options for the Lithium battery pack in the conversion kit?

When considering a Lithium battery pack for your conversion kit, you have several options to choose from, each with varying capacities and charging capabilities:

1. 66 kWh Pack with 10 kW Charger
   Ideal for high-capacity needs, this option pairs a sizable 66 kWh battery pack with a robust 10 kW charging kit for faster charging times.
2. 22 kWh Pack with 3 kW Charger
   This option is perfect for smaller applications, offering a 22 kWh pack alongside a 3 kW charging kit.
3. 44 kWh Pack with 3 kW Charger
   Balancing capacity and charging speed, this setup provides a 44 kWh battery pack with a 3 kW charger.
4. 5x Tesla Modules (26.5 kWh) with 3 kW Charger
   Comprising five used Tesla LiPo modules, this choice delivers 26.5 kWh and includes a 3 kW charging system.
5. 10x Tesla Modules (53 kWh) with 3 kW or 10 kW Charger
   This offers a large capacity of 53 kWh using ten used Tesla LiPo modules. You can select a 3 kW or more powerful 10 kW charger based on your charging requirements.
6. LifePo4 Pack (28 kWh) with 3 kW Charger
   Featuring a LifePo4 battery technology, this option offers 28 kWh with a 3 kW charging kit for efficient power usage.

Each option suits different energy needs and charging preferences, allowing you to tailor your selection based on the specific requirements of your project.

What is the price range for the complete EV conversion kit?

The complete EV conversion kit is available at a price range, starting from €7,770 up to €26,300, excluding VAT.

What charging solutions are available as part of the optional battery pack?

The optional battery pack offers a comprehensive suite of charging solutions designed to meet diverse needs. Here’s what’s included:

• Diverse Battery Options: Choose from a variety of lithium batteries, each equipped with an advanced Battery Management System (BMS) for optimal performance. Enjoy seamless connectivity with an integrated circuit board and Bluetooth application for easy monitoring.
• Charger Options: You can opt for either a standard 3.3 kW charger controlled via the vehicle’s CAN system or go for an enhanced 10 kW, 3-phase charger. Both options come with a complete connection kit featuring pre-assembled cables that are 3 meters long, providing convenience and efficiency.
• Convenient Charging Socket: The package includes a Type 2 charging socket on the vehicle side, ensuring compatibility with a wide range of public and home charging stations.

This flexible and versatile package ensures you have the necessary components for efficient and reliable vehicle charging, whether you’re at home or on the go.

Are the components of the EV conversion kit pre-assembled and tested?

Absolutely, the components of the EV conversion kit are pre-assembled and tested. Unlike many other suppliers that provide kits with numerous loose parts, this kit is designed for a streamlined conversion process. It includes components that are as pre-assembled as possible, ensuring they are already programmed and tested for functionality. This thoughtful design means you’ll spend less time on labor and more time enjoying your newly converted electric vehicle.

What are the optional components available with the EV conversion kit?

Optional Components for Your EV Conversion Kit

When enhancing your electric vehicle conversion, several optional components can optimize performance and functionality:

• Lithium Battery Options: Choose from a range of lithium batteries equipped with a certified Battery Management System (BMS) for safe and efficient energy management. Enjoy seamless integration with the included connection circuit board and take advantage of Bluetooth app capabilities for real-time monitoring.
• Charging Solutions: Opt for an Original Equipment Manufacturer (OEM) controlled charger available in two configurations— a robust 3.3 kW charger or a powerful 10 kW, 3-phase solution. Each comes with a connection kit featuring pre-assembled cables measuring 3 meters for hassle-free installation.
• Charging Interface: Integrate a Type 2 charging socket, known as the “Mennekes” connector, on the vehicle side to ensure compatibility with a wide range of public charging stations.
• High Voltage Service Disconnect: Enhance safety with a service disconnect that includes an interlock mechanism, ensuring secure operations during maintenance.
• Cabling and Connectors: The kit features high-quality orange high-voltage cables as per European standards, including an 8-meter shielded cable and an additional 2-meter cable, both 50 mm² in size. It is complete with 16 cable lugs and a 6-meter CAN communication cable for comprehensive connectivity.
• Installation Components: All essential buttons and plugs are included for a complete and efficient electric vehicle conversion.

These optional components offer a robust solution to customize your EV conversion, enhancing functionality and safety for a seamless transition to electric driving.

What additional items are not included in the EV conversion kit?

Additional Items Not Included in the EV Conversion Kit

For a comprehensive understanding of what is not part of the EV conversion kit, please consider the following:

• Battery Trays:While these are essential for securing the batteries, they must be acquired separately. If custom designs are needed, these can be arranged for an additional cost.
• DC Heater:This is not part of the base kit but there are multiple options available on the market that can be integrated according to your specific requirements.

Remember, additional components and modifications might be required depending on your specific vehicle and personal customization desires.

What are the dimensions of the assembly drawing for the EV conversion kit?

The assembly drawing for the EV conversion kit features dimensions key to its setup: 2018 by 912, labeled as the 912 E-hype. This specification provides precise measurements essential for fitting and integrating the conversion components.

What certifications do the components of the EV conversion kit have for use in the EU?

Certifications for EU Authorization of EV Conversion Kit Components

The components of the EV conversion kit are certified for compliance and authorization throughout EU countries, ensuring top-notch safety and performance standards. Below are the key certifications obtained:

• Propulsion System Certification:
  • The propulsion system is certified under R10, revision 5, highlighting compliance with essential automotive electromagnetic compatibility (EMC) standards.
• Battery Management System (BMS) Certification:
  • The BMS meets the requirements of R10, revision 4, ensuring it upholds the highest standards for electronic device safety and performance under electromagnetic exposure.
• Component Compliance:
  • Components are CE certified, aligning with key European directives and standards:

2. Low Voltage Directive (LVD) 2014/35/EU:Ensures the electrical safety of the components when operating at defined voltages.
3. Electromagnetic Compatibility (EMC) Directive 2014/30/EU:Confirms that components do not emit excessive electromagnetic interference and are immune to normal levels of electromagnetic disturbance.
4. EN 60335-1:2012:Relates to the safety of electrical appliances, safeguarding against potential hazards under normal handling.
5. EN55014-1:2006:Specifies standards for household appliances, electrical tools, and similar apparatus regarding electromagnetic compatibility.
6. EN50498:2010:Concerns the electromagnetic compatibility requirements for aftermarket electronic equipment designed for connection to the vehicles, explicitly addressing automotive equipment.

By ensuring these certifications, the EV conversion kit is well-equipped to meet the stringent safety and compliance standards required within the EU market.

How is the EV conversion kit designed to simplify the conversion process?

So, Steve discovered that building an electric vehicle is not for the faint of heart. It’s more like a full-contact sport. But, if you’re up for the challenge, he suggests getting a complete kit from a trusted company to simplify the process and save some dough.

Why Choose a Complete Kit?

A complete EV conversion kit can make the process much smoother by providing:

• Pre-assembled Components: Unlike other kits that come as a jumble of parts, a complete kit offers pre-assembled components. This means less time spent figuring out how everything fits together.
• Programmed and Tested Systems: The components aren’t just thrown together; they’re programmed and tested to ensure they work seamlessly. This takes a significant amount of guesswork out of the equation.
• Reduced Labor: With most of the hard work done for you, the labor required is minimal. This not only saves time but also reduces the complexity of the project, making it accessible even for those who aren’t seasoned mechanics.

If you’re considering the leap into EV conversion, a comprehensive kit could be your best play. It simplifies the process, allowing you to focus on enjoying the journey rather than getting bogged down in technical details.

Are there options available for customization?

Yes, the kit offers various options for Lithium battery systems, allowing for customization based on specific needs or preferences.

How does the kit impact labor requirements?

The kit is designed to minimize labor, requiring significantly less time and effort for conversion due to its simplified assembly.

How is the complexity of the installation process addressed?

By providing pre-assembled and tested components, the kit simplifies the installation, making it more accessible and less daunting.

What does the kit include?

The kit features components that are pre-assembled, programmed, and tested, ensuring a smoother conversion process compared to loose parts.