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Unread 11-25-2010, 02:47 PM   #1
robin w.
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Default Electric 944 conversion

Hello everyone, I'm obviously new here. I was refered to this forum by a fellow 944 owner. I have an '83 944 that I am fixing up as a regular gas car as well as an '86 944 that I am converting to electric power. I will be using a series wound DC motor connected to the bell housing and torque tube to drive a stock 944 turbo tranny. The gas engine and all related components (cooling system, fuel system, exhaust system, etc.) have been removed making room for the DC motor, DC motor controller and a fairly large pack of LiFePO4 batteries. Range will be around 100-150km per charge depending on driving speed and style, power will be around 300hp and 300ft-lbs of torque.

The '86 started out as an NA donor that the previous owner had swapped in the turbo tranny. It's a bit slow off the line with the NA engine, but gets pretty good mileage. The electric motor can generate 300ft-lbs of torque from 0-5000 rpm so even with the higher ratio of the turbo tranny I'll probably be starting off in 2nd gear to avoid roasting the tires.

There will be no regen on this car, as it will be using "older" dc motor technology very similar to what's found in an electric forklift, just at much higher voltage/current and power levels.

I've only owned my 944's for a short time, but after a few months of driving the '86 I fell in love with it. I hope you guys can see this conversion in a positive light, I'm taking a great car, and turning it into something that is ECO friendly and with lower maintenance, but still keeping it's performance roots and great looks.

The car:
Click the image to open in full size.

Click the image to open in full size.

A few of the batteries, the car will be powered by 630 of these cells:
Click the image to open in full size.

The motor, with the stock (blown) 2.5L and starter for size reference:
Click the image to open in full size.

Click the image to open in full size.

If you have any comments or questions I would be happy to hear them. There are many small things I've left out, like charging, heating, power steering, brake booster vacuum and all that but I'll make some small updates as I install those systems. Right now I'm working on getting the gas 944 on the road, I bought it with a blown engine and am swapping the engine from the '86 into it.
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Unread 11-25-2010, 03:02 PM   #2
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Welcome, Robin! I've followed some of your electronics work on another forum, and I know we'll be interested to see how the project goes!
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Unread 11-26-2010, 05:18 PM   #3
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Hope you can find a good solution for weight/balance- I'm not sure how much all of that weighs.

Definitely post more details about it, especially relating to the clutch/disengagement mechanism for shifting (if you need it).
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Unread 11-27-2010, 07:30 PM   #4
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Quote:
Originally Posted by Joel View Post
Hope you can find a good solution for weight/balance- I'm not sure how much all of that weighs.

Definitely post more details about it, especially relating to the clutch/disengagement mechanism for shifting (if you need it).
Thanks for the comment, weight balance shouldn't be a problem, I've been keeping track of all the weight removed from the car and will do my best to put it back in the same places. The car will gain about 100-150lbs over stock, so it could be brought back down/below stock weight with the right weight reduction, however a doubling of HP/Torque should make up for it.

As for the clutch it's staying for now, but it's only required for changing gears and not starting/stopping so if it can handle the torque it will virtually last forever. If it can't handle the torque that's another story, and I may end up with a clutchless setup depending on how well it shifts.
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Unread 12-10-2010, 02:12 AM   #5
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I would think with an increase in weight of less then one passenger (standard is 180#) not much would be affected. It is the balance issue that would concern me more. The 944 was about perfectly balanced (if underpowered) so placement would be essential to keep the personality of the car. I will watch this thread with interest.
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Unread 12-10-2010, 07:39 AM   #6
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Awesome! I'll be watching.
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Unread 12-10-2010, 08:31 AM   #7
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Very cool project.
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Unread 12-10-2010, 11:08 AM   #8
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Unread 08-16-2013, 11:56 PM   #9
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Well it's been WAY too long since I've updated here.

Click the image to open in full size.

The car is mostly done, and my daily driver. Just got some new suspension on it to bring up the back and lower the front.

It gained 300lbs on the rear and lost 100lbs on the front. F/R balance is about the same as a Cayman now and I really like it.

Click the image to open in full size.

Most of the batteries are in the rear, sunk in the floor where the gas tank and spare tire use to reside.

Click the image to open in full size.

In the front you can see the battery box where the rad use to be before I installed the batteries. You can also see the front of the motor and stock AC.

I think I need to get some new pictures of the almost final product.

I love the car though, it's fast, handles amazing with plenty of power.
It'll do 0-60mph in 5 seconds flat with ease right now, but there's room for improvement with software tuning in the controller as well as some extra batteries I'm about to install. Might need some wider rubber though, that's on 215/60R15's and I have to baby it a bit off the line when I launch in 2nd gear (turbo transmission) it's still pretty easy to break the tires loose.

My new goal is 0-60 in 4.4 seconds or exactly half of what the car did as a stock '86 NA.
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Unread 08-28-2013, 04:50 PM   #10
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Robin, that's sensational work.

Does the AC compressor only get turned when the car is moving, or do you idle the electric motor? Does the car still have its computer and gauges, or do you have something custom for that, too?
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