Final drive ratio in an electric conversion car

Electric Bug

So, I’m getting a new transmission for my VW bug (number 3), and probably buying it from http://www.mofoco.com/category/Rebuilt_VW_Transmissions/c112. What drive ratio should I get? They can do a few different options.

My bug is/was currently running the stock stuff for a 69 bug:

Screen Shot 2014-09-04 at 6.10.30 PM.png

I have 165R15 coker tires, and the diameter was calculated via:

http://www.evsource.com/motor_calculator.php &

http://store.cokertire.com/tire-styles/radial-tires/wide-whitewall/165r15-bfg-2-1-4-whitewall.html

The ratios I got from the VW manual, and the screen shot is from my Numbers spreadsheet (email me and I’ll send it to you).

Here are my current speeds for a given RPM and a given gear. Max motor RPM is around 5000 (maybe 5500, but that is pushing it), so I have to shift before then. I don’t use first; it is pointless (I have enough torque to not need it), too jerky, and would have to quickly shift.

Screen Shot 2014-09-04 at 6.12.07 PM.png

I always start in 2nd, shift into 3rd at about 40mph, and 4th at 65mph; this keeps me under the 5,000 RPM limit. I have a top speed of a bit under 100mph, based on the RPM.

So, the diff ratio is 4.375 (also called 4.38); also known as the “ring and pinion” gear ratio. What if I get a freeway flyer 3.88 ring and pinion? Dropping that into my spread sheet gives

Screen Shot 2014-09-04 at 6.19.11 PM.png

So, if I did this, I would: start in 2nd, shift to 3rd at about 45 mph, and shift into 4th at about 75 mph. I rarely go 75 mph; the car starts to shake a bit at high speeds, and it just isn’t designed to do that. The lower ratio would probably make the car less torquey, so I’ll stick with the standard ratio.

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