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kiwipip Samba Member
Joined: July 23, 2018 Posts: 76 Location: New Zealand
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Posted: Sun Nov 06, 2022 9:41 pm Post subject: 61 Double Cab EV Conversion Build thread |
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What seems like eternity, I can finally start the reassembly of the DC. I purchased the DC in 2018 after after it had been sitting for 8 years with the majority of body work completed what was a very solid vehicle to start with.
Well 4 years later (COVID didn't help), its finally back home and the assembly and all the parts I have accumulated over the years can start tone installed.
The DC was a solid vehicle to start with
Back to bare metal and countless hours of prep to get it straight
Final paint ready for assembly
First thing get the doors back on
The underside was just as detailed as the top side
a mix between smooth and textured finishes
Last edited by kiwipip on Sat Nov 19, 2022 9:14 pm; edited 1 time in total |
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kiwipip Samba Member
Joined: July 23, 2018 Posts: 76 Location: New Zealand
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Posted: Sun Nov 06, 2022 9:45 pm Post subject: Re: 61 Double Cab Build Thread |
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Cleaned to Cargo Door Latch and installed it
Dynamite to the doors |
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zimblewinder Samba Member
Joined: January 22, 2004 Posts: 893 Location: Australia
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Posted: Mon Nov 07, 2022 1:55 am Post subject: Re: 61 Double Cab Build Thread |
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great colour, looks a lot like Rob Kings DC here in Oz back in the day. _________________ 58Euro 23 343208 The Ultimate Zimblewinder Machine.
59 mango standard
Wanted- splash pan supports, og pressed bumper coach bolts, ivory blaupunkt knobs (early), armrest alloy strips, NOS door mechanism |
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Huetti_1989 Samba Member
Joined: February 13, 2011 Posts: 1136 Location: Austria
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Braukuche Samba Member
Joined: September 03, 2004 Posts: 11005
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Posted: Mon Nov 07, 2022 7:42 am Post subject: Re: 61 Double Cab Build Thread |
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Wow, starting with a truck that straight and dry is like hitting the lottery. _________________ Go Reds! Smash state!
Retirement is here!
1956 Ghia
1959 SO-23 Westfalia
1960 double cab
1960 Baja Bug
1963 stretched double cab
1962 Golde sunroof Ghia
1963 356 B coupe
1963 Notchback
1967 21 window less rusty now |
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kiwipip Samba Member
Joined: July 23, 2018 Posts: 76 Location: New Zealand
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Posted: Mon Nov 07, 2022 8:38 pm Post subject: Re: 61 Double Cab Build Thread |
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Managed to get both front doors lined with Dynamat, locks and strikers cleaned buffed and installed and all aligned. Just waiting for the chrome platers to finish so i can install the glass.
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kiwipip Samba Member
Joined: July 23, 2018 Posts: 76 Location: New Zealand
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Posted: Wed Nov 09, 2022 10:19 pm Post subject: Re: 61 Double Cab Build Thread |
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Sorry guys Im posting lots of pics on a daily basis, as Im using the forum to document my rebuild like a Diary.
Today I managed to finish the Dynamat Liner including the roof
Installed the front Bullet Blinkers
Installed the EV Charge Flap
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kiwipip Samba Member
Joined: July 23, 2018 Posts: 76 Location: New Zealand
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Posted: Sat Nov 12, 2022 9:45 pm Post subject: Re: 61 Double Cab Build Thread |
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Started on some of the wiring, Attached the bullet indicators and the Head light Loom.
Made some mock ups of the Tesla Battery Packs that will sit under the rear bench seat
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BarryL Samba Member
Joined: November 01, 2004 Posts: 14277 Location: Casa de Oro, California
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Posted: Sun Nov 13, 2022 6:51 pm Post subject: Re: 61 Double Cab Build Thread |
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Did you post somewhere you were going electric with this? |
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kiwipip Samba Member
Joined: July 23, 2018 Posts: 76 Location: New Zealand
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Posted: Sun Nov 13, 2022 10:49 pm Post subject: Re: 61 Double Cab Build Thread |
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BarryL wrote: |
Did you post somewhere you were going electric with this? |
No up till about 4 months ago I was going down the conventional route even built the motor which is now sitting in my Man Cave. Im a bit reluctant to mention the EV Conversion as there are many haters. The conversion Im doing uses all the standard components with no body modifications, all the electrics modules and battery pack sit in a battery bot under the rear seat so no one will be the wiser.
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Mikee Samba A.D.D. Boy
Joined: March 22, 2004 Posts: 3510 Location: Puyallup WA
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Posted: Sun Nov 13, 2022 11:27 pm Post subject: Re: 61 Double Cab Build Thread |
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That motor would look good in my bus!!
kiwipip wrote: |
BarryL wrote: |
Did you post somewhere you were going electric with this? |
No up till about 4 months ago I was going down the conventional route even built the motor which is now sitting in my Man Cave. Im a bit reluctant to mention the EV Conversion as there are many haters. The conversion Im doing uses all the standard components with no body modifications, all the electrics modules and battery pack sit in a battery bot under the rear seat so no one will be the wiser.
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_________________
localboymark wrote: |
One man's "patina" is another man's cancer. |
bugnut68 wrote: |
I would have kicked the guy right in the dick, balls, ass and face and destroyed his weed. Hippies suck. |
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Glenn Mr. 010
Joined: December 25, 2001 Posts: 76969 Location: Sneaking up behind you
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Posted: Mon Nov 14, 2022 6:13 am Post subject: Re: 61 Double Cab Build Thread |
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You should dump that Kultek POS distributor and get a real 010. _________________ Glenn
74 Beetle Specs | 74 Beetle Restoration | 2180cc Engine
"You may not get what you pay for, but you always pay for what you get"
Member #1009
#BlueSquare |
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Braukuche Samba Member
Joined: September 03, 2004 Posts: 11005
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Posted: Mon Nov 14, 2022 8:15 am Post subject: Re: 61 Double Cab Build Thread |
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What sort of range are you looking at with the EV conversion? _________________ Go Reds! Smash state!
Retirement is here!
1956 Ghia
1959 SO-23 Westfalia
1960 double cab
1960 Baja Bug
1963 stretched double cab
1962 Golde sunroof Ghia
1963 356 B coupe
1963 Notchback
1967 21 window less rusty now |
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kiwipip Samba Member
Joined: July 23, 2018 Posts: 76 Location: New Zealand
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Posted: Mon Nov 14, 2022 11:18 am Post subject: Re: 61 Double Cab Build Thread |
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Braukuche wrote: |
What sort of range are you looking at with the EV conversion? |
I’m expecting somewhere around the 100~120 mile range, if I wanted to double the range I double the battery storage as there is ample room under the rear seat for double the battery capacity but adds another roughly $9K USD to the kit.
Range wasn’t an issue for the build as it will be used on the odd weekend to go the the local shops etc. I have a few great cars and if I wanted to go in an extended trip the DC would be my last choice in a long distant jaunt for safety speed or comfort |
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Braukuche Samba Member
Joined: September 03, 2004 Posts: 11005
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Posted: Mon Nov 14, 2022 2:12 pm Post subject: Re: 61 Double Cab Build Thread |
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kiwipip wrote: |
Braukuche wrote: |
What sort of range are you looking at with the EV conversion? |
I’m expecting somewhere around the 100~120 mile range, if I wanted to double the range I double the battery storage as there is ample room under the rear seat for double the battery capacity but adds another roughly $9K USD to the kit.
Range wasn’t an issue for the build as it will be used on the odd weekend to go the the local shops etc. I have a few great cars and if I wanted to go in an extended trip the DC would be my last choice in a long distant jaunt for safety speed or comfort |
Thanks for the info.
I was curious because I think a double cab makes a perfect candidate for conversion without messing up the original metal of the vehicle or having to take up usable space for batteries. _________________ Go Reds! Smash state!
Retirement is here!
1956 Ghia
1959 SO-23 Westfalia
1960 double cab
1960 Baja Bug
1963 stretched double cab
1962 Golde sunroof Ghia
1963 356 B coupe
1963 Notchback
1967 21 window less rusty now |
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Dangermouse Samba Member
Joined: November 23, 2005 Posts: 1266 Location: Beautiful New Zealand
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Posted: Mon Nov 14, 2022 8:07 pm Post subject: Re: 61 Double Cab Build Thread |
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That is such a sweet truck; whereabouts are you? So looking forward to seeing this out there. Inspirational stuff for me still at the crusty end of my single cab project _________________ Do not follow me, for I may not lead. Do not lead me, for I may not follow. Do not walk beside me either; actually just bugger off and stand over there will you. |
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kiwipip Samba Member
Joined: July 23, 2018 Posts: 76 Location: New Zealand
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Posted: Mon Nov 14, 2022 10:30 pm Post subject: Re: 61 Double Cab Build Thread |
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Dangermouse wrote: |
That is such a sweet truck; whereabouts are you? So looking forward to seeing this out there. Inspirational stuff for me still at the crusty end of my single cab project |
Im in Auckland the DC is at my man cave in St Johns, don't know where you are based but you more than welcome send me a PM and I can flick you my number and you can have a look cheers |
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Dangermouse Samba Member
Joined: November 23, 2005 Posts: 1266 Location: Beautiful New Zealand
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Posted: Tue Nov 15, 2022 7:15 pm Post subject: Re: 61 Double Cab Build Thread |
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Ah, I'm down the other end, in Dunedin. Otherwise I'd be straight around for a look... But will be following this thread with great interest. That underside; so clean you could eat your dinner off it _________________ Do not follow me, for I may not lead. Do not lead me, for I may not follow. Do not walk beside me either; actually just bugger off and stand over there will you. |
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kiwipip Samba Member
Joined: July 23, 2018 Posts: 76 Location: New Zealand
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Posted: Wed Nov 16, 2022 10:39 pm Post subject: Re: 61 Double Cab Build Thread |
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Was up under the Dash today have done the bulk of the wiring, Just waiting for Turn Signal switch to come back from the painters (Red same as the Dash) then that will be completed. Installed the Headlights another "What I thought would be a 5 minute job" once again bite me on the Ass but they are in.
Thank God for this forum and Google as I never tore down the DC the little things get me baffled like (How the fuse box stays in the holder mmm a little spring clip,, How the rear lid stay operates how does the spring attach and a little thing like where do I mount the Earth strap as I thought that hole was for the engine lid stay.
Hopefully next week I can install the new Discs for front and rear, install brake lines etc
Headlights installed
Wiring all but completed just waiting for the refurbished speedo to finish the last of the remain wires test it the secure and tidy it all up
So this is where the Earth strap mounts. (yes I marked it ground it to bare metal and used some Dielectric grease to ensure a good contact |
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kiwipip Samba Member
Joined: July 23, 2018 Posts: 76 Location: New Zealand
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Posted: Sat Nov 19, 2022 9:39 pm Post subject: Re: 61 Double Cab EV Conversion Build thread |
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I have edited the title to EV Build, I know there will be plenty of haters and purists that will persecute me for doing this, but I have made sure this is a bolt in kit. There are body modifications all the battery packs controllers etc fit under the rear seat, uses the existing throttle pedal etc.
If at a later date someone wants to convert it back it just a matter of unbolting the EV Motor of the gear box and remove the Battery box from under the rear seat.
Kit arrived from Netherlands
Motor and Tesla Battery Modules
The Old and the New
Charge port a perfect fit in the existing gas filler location |
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