Electric Bug

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Plug Bug: Batteries

How about just some pictures?
Electric Bug
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Plug Bug: Rear Battery Box

Don’t forget about the original design: http://www.corbinstreehouse.com/blog/2010/12/plug-bug-battery-box-design/ I did modify it slightly as I went along. I learned a lesson from the front box: add 1/8″ or so to the total length to avoid it... [read more]
Electric Bug
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Plug Bug: Front battery box fabrication

I’ve been working on fabricating the battery boxes out of 1/8″ steel angle iron and flat stock for the past two weeks. The first step was to strap them together to get an accurate measurement... [read more]
Electric Bug
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Plug Bug: Strapping Thundersky batteries together

Here’s how I strap the Thundersky batteries together. As previously mentioned, I bought the Mini Polyester Strapping Kit 5/8″ x .040″+seals + tools for $80 (plus shipping) on ebay. The pack of 4 (or 5)... [read more]
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Plug Bug: Weight Distribution

The unladen weight of the stock bug is 1807 lbs. The gross vehicle weight is 2645 lbs. Front axle load: 1080 lbs, rear: 1609 lbs. The front axle had the 10.6 gallon tank removed —... [read more]
Electric Bug
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Plug Bug: Battery Box Design

I did some research on what people have done for battery boxes. The cells need to be contained well so they don’t go flying around in the event of an accident. A few interesting posts... [read more]
Electric Bug
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Plug Bug: Batteries Arrived!

I’m a little behind on the status of the project…I got the batteries on Dec 8th, but was really busy that week due to Louise’s show, Left of the North Pole. It was a pain... [read more]
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Plug Bug: Gas Gap Sticker

My batteries are in California! I just need to have the guy call me to pick them up. I’m dying to get them and put the car together, but in the meantime here’s what I... [read more]
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Plug Bug: Stereo

I wanted to have a good sound system in the car. I bought an Alpine stereo and a set of speakers. I was initially going to mount them in the doors, but I read that... [read more]
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Plug Bug: Auxillary 12 v Battery

A typical gas powered car has a large 12 volt battery mainly for the purpose of turning the engine over during starting. That usually takes a lot of amps to crank it over. Since my... [read more]
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Plug Bug: iPad mount

It’s raining today but I did add a cool option to my car. The iPad mount! I was originally going to make my own mount, but that would take days of machining time and would... [read more]
Electric Bug
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Plug Bug: Electric Ceramic Heater

I got my heater installed; I can test the fan and make sure the contactor comes on, but heat won’t come out until I actually have my battery pack installed. I cut a hole on... [read more]
Electric Bug
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Plug Bug: Wiring…and more wiring

I’m still waiting for batteries, but i’m getting a lot of the little details done. The car could be drivable if I actually had a battery pack. I can turn on the key and hear... [read more]
Electric Bug
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Plug Bug: Wires and Hoses

More progress tonight. Here’s aluminum L angle pieces to mount the radiator on. I slotted the car with a 4.5″ angle grinder (plus a cut off wheel) to keep the L shape and make the... [read more]
Electric Bug
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Plug Bug: Motor backing plate + Controller

The project is moving along slowly. I was pretty busy with other things last week and didn’t get much time to work on it. I wanted a 1/8″ sheet of aluminum to back the motor... [read more]
Electric Bug
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Plug Bug: Interface Module Installed

I worked on the bug a bit yesterday but didn’t get much done; things go slow! I ordered a Heater Kit from Canadian Electric Vehicles – http://www.canev.com/KitsComp/Components/Heater.html — the easiest way to do a heater... [read more]
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Plug Bug: Motor Installed

Last weekend was a big weekend for the project. My buddy Aaron, who has a lot of home-built EV experience and now works at Tesla came over to lend me a hand. He brought over... [read more]
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Plug Bug: Wheel and Rim

A quarter shot of the bug with the painted wheels, white walls and new dome style hubcaps (from CIP1):
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Plug Bug: Seats Upholstered

Not much to say, but I got a bunch of the rust off of the seats, fixed some broken parts, painted them and then put them back together with new foam. I got new seat... [read more]
Electric Bug
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Plug Bug: Wheel Selection

My rims started out like this, with a bunch of rust on the sides and white painted part: I thought it wouldn’t be too hard to clean them up, but I was wrong! After some... [read more]
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Plug Bug: Turning the flywheel

An electric motor doesn’t need a big flywheel to keep the engine running. It also doesn’t need the starter gear teeth around the edge. In fact, all it really has to do is engage with... [read more]
Electric Bug, Machining
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Plug Bug: Speedometer Repair

The speedo in the bug was broken. Ed, who I bought the car from, said it was just the cable that needed replacing and that he had replaced it a few times. I suspected something... [read more]
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Plug Bug: Window / Door Restoration

I needed to replace the seals in the little vent windows and put in a new handle. This involves pulling the glass out out of the vent window channel and riveting on a new handle.... [read more]
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VW Bug Restoration Links

General Tips on Restoration Classic VW Bugs – http://www.classicvwbugs.com/restotips.htm – Lots of videos on how to do various restoration items.. This is where I first learned how to install windshield, and he gave a great... [read more]
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Plug Bug: Battery Delay :(

Well, the project’s batteries are going to be delayed. I checked up on the battery status, and it turns out there was a mishap with the order – Evolve Electrics goes through Alliance Batteries, which... [read more]
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Plug Bug: Headliner Install

I was really nervous about installing the headliner. I heard it was really hard to do, and frequently didn’t come out right or required a second headliner due to the first one getting messed up.... [read more]
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Plug Bug: With the hood

I ordered the wrong seal for the hood, but I finally got the new one and stuck it on. The car is looking great! It looks really high in the rear since there is no... [read more]
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Plug Bug: Luggage panel replaced

Note: this post is out of order; I did this quite a while ago, but our internet (Surfnet Wifi) has been down at home. The rear luggage floor, behind the rear seat, was rotten with... [read more]
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Plug Bug: Two tone bug

I finally pulled some pictures of the final painting of the car. No front picture yet, as I haven’t put on the hood (I bought the wrong seal). I’m quite happy with the result. Metallic... [read more]
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Plug Bug: Red Paint

I basically have two jobs right now; working at Apple by day, and being a car painter at night and on the weekends. I’ve been working really hard to get the primer all sanded smooth... [read more]
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Plug Bug: Primered

Let the painting begin! On Saturday, I went to Santa Cruz Auto Parts and picked out a metallic red and metallic silver that I liked. It took me quite a while, and I hope the... [read more]
Electric Bug

(c) 2008-2019 Corbin Dunn

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