| (2007 - 06/09) | Phase 1 | was the planning stage and began about a year before the conversion began.
This involved selecting the components to go in it, where this would come from, buying the donor car etc.
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| (7/6/09 - 07/18/09) | Phase 2 | began while I was still driving it as a gas car.
This stage simply involved removal of all the gas related components.
I began by removing the exhaust system and still drove it around (LOUD) for a couple more days.
Then I removed the gas tank and all fuel lines, rendering the Golf undriveable until the conversion was completed.
I also pulled out the engine in this stage.
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| (6/24/09 - 9/10/09) | Phase 3 | was the most complicated and involved phase where all the electric components were installed.
I started off by fabricating a battery rack in the trunk area to hold 8 batteries and the charger.
The electric motor was fitted with the original flywheel assembly and mounted to the transmission.
I also modified the motor mount that came with the motor for a good custom fit to the car.
Next, I built a battery rack under the hood to hold 4 more batteries.
I mounted all the control components to an aluminum plate on hinges mounted to the firewall with access to the motor.
This phase ended the day I successfully drove the electric car.
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| (9/14/09 - forever) | Phase 4 | is an ongoing phase that includes all the non-conversion specific modifications that I'm doing while the EV is complete.
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| Phase 1 | 100 | | Estimated planning time
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| Phase 2 | 16 total |
| 1 | 7-6-09 | Muffler Removal |
| 4 | 7-9-09 | Remove gas tank, fuel lines, radiator, hoses, almost everything connected to the engine |
| 3 | 7-10-09 | More parts removal |
| 5 | 7-18-09 | Remove engine, other stuff |
| 2.5 | 7-19-09 | Remove most of heat shields, clean engine compartment |
| 0.5 | 7-30-09 | Remove last heat shield |
| Phase 3 | 108.5 total |
| 10 | 5-9-09 | Mount all components, wire, complete 144V & 12V, 8ft test drive, first charge |
| 4 | 6-24-09 | Battery Box Design |
| 8 | 6-28-09 | Battery box rack fabrication |
| 3 | 7-12-09 | Finishing welding battery rack and other component removal |
| 3 | 7-14-09 | More battery rack, paint battery rack, get engine hoist |
| 1.5 | 7-19-09 | Mount flywheel to motor |
| 3 | 7-21-09 | Tach adaptor design, machine magnet mount |
| 6 | 7-23-09 | Motor prep & input |
| 7 | 7-24-09 | Motor mounting, front battery rack fab |
| 5 | 7-26-09 | Fab last battery rack, "machine" aluminum mounting plate |
| 2 | 7-29-09 | Finish mounting Al plate and try to arrange components |
| 4 | 7-30-09 | Mount conduit, mounting component planning |
| 4 | 8-2-09 | Machine custom parts |
| 1 | 8-4-09 | Test battery fit and parts |
| 1 | 8-10-09 | Pull wire through conduit and stuff |
| 1 | 8-11-09 | Finalize tach adaptor, get more batteries |
| 1 | 8-13-09 | ? |
| 3.5 | 8-14-09 | Fab PS mount, machine starter cover plate & install |
| 7 | 8-15-09 | Lots of component mounting |
| 1.5 | 8-21-09 | Mounting power steering pump and vacuum switch |
| 6 | 8-22-09 | Wiring various stuff |
| 5 | 8-24-09 | Machining |
| 4 | 8-24-09 | Wiring 12v dist |
| 1.5 | 8-25-09 | Wiring 120 VAC box in gas inlet |
| 1 | 9-1-09 | Start sanding AL plate |
| 2 | 9-4-09 | Begin mounting components to plate |
| 4 | 9-6-09 | Wire & install gage pod |
| 4 | 9-7-09 | Wire & test PS pump, mount gauge pod, attempt diagnose weeee sound |
| 1.5 | 9-9-09 | Finish sanding AL plate |
| 3 | 9-10-09 | Final hookup and test drives |
| Phase 4 | 23 total |
| 2 | 9-14-09 | Attempt to wire second battery remote |
| 4 | 9-15-09 | Wire remotes, redo 2/0 in front, fix temp |
| 2 | 9-24-09 | Sub box design |
| 5 | 9-26-09 | Build sub box, figure out battery leak |
| 3 | 9-27-09 | 12V aux battery, balance battery acid levels |
| 6 | 9-27-09 | More box building, wire 12V aux batt |
| 1 | 9-28-09 | Caulk box, apply website tattoos |
. Thanks.