Goal
Commuter car with 30 miles of range. May extend range later with more batteries.
Car
2001 BMW 325i Wagon
Purchased from salvage auction in Indianapolis. It was a donation with a clean title, but 200k miles and in mechanically rough shape. Shipping cost more than the car.
Interior
Sunroof delete AJ Hartmann CF sunroof panel, painted at home with rattle cans.
Ordered black slicktop headerliner and trim pieces from Scheidmann in Denamark. Shipping was 50% of cost, but the old grey interior was in rough shape and no slicktop headliners in the US.
Gutted the rear to put battery and other support gear in. Hope to move batteries to engine bay and restore the interior eventually.
Battery
2012 Chevy Volt Battery Pack
Mainted as much as the stock configuration as possible. Had to cut it into 3 sections and mount to a plywood platform to get it to fit in the car.
Created a custom PCB with a teensy to be the controller for the battery, charger, and APM. It drives everything in the front part of the battery: contactors, pre-charge, battery heating, CAN monitoring.
Charger
Chevy Volt Charger
APM
V1: Chevy Volt APM
V2: Tesla Model S 12V Module
Drivetrain
Lexus GS450h transmission and Inverter
VCU
EVBMW Zombieverter VCU
Power Steering
V1: Garagistic Power Steering Delete Block
V2: Volvo Electric Power Steering Pump
Cabin Heat
V1: Harbor Freight 12V Defroster
V2: Chevy Volt Heater
V2: Tesla Battery Heater
Air Conditioning
Tesla A/C Compressor
Brakes
UP-28 Vacuum Pump