Help Support Bigcoupe.com

Electrifying my '85 635CSi Euro

Document your Sixer project here.

Moderators: ron, bfons, GRNSHRK

Quietlion79
Posts: 39
Joined: Sat Nov 16, 2019 10:29 pm
Location: Los Angeles

Re: Electrifying my '85 635CSi Euro

Post by Quietlion79 » Sat Nov 23, 2019 2:03 am

@mdkohler

Hello, I am planning on converting my auto 81 Euro 635csi to a 5 speed manual and would potentially interested in the 5 speed transmission, some clutch parts and the flywheel. If you could send me the part number for the transmission and the weight of the flywheel, I would appreciate it.
1952 Austin Sheerline Limo RHD
1963 Chrysler 300J 413 Dual Quad
1963 Studebaker Avanti R2 4 spd SC
1964 Jensen CV8 Mk2 383 RHD
1970 AMC Rebel Machine 390 4 speed
1981 BMW Euro 635CSI
1989 Chrysler Conquest 2.6 turbo
2001 Honda Insight 5 spd

Quietlion79
Posts: 39
Joined: Sat Nov 16, 2019 10:29 pm
Location: Los Angeles

Re: Electrifying my '85 635CSi Euro

Post by Quietlion79 » Wed Nov 27, 2019 4:35 pm

Regenerative braking is the isht. Some people in the forum of my DD, gen1 Honda Insight, have NEVER changed their rear brakes, even after hundreds of thousands of miles.
1952 Austin Sheerline Limo RHD
1963 Chrysler 300J 413 Dual Quad
1963 Studebaker Avanti R2 4 spd SC
1964 Jensen CV8 Mk2 383 RHD
1970 AMC Rebel Machine 390 4 speed
1981 BMW Euro 635CSI
1989 Chrysler Conquest 2.6 turbo
2001 Honda Insight 5 spd

User avatar
mdkohler
Posts: 65
Joined: Tue Sep 17, 2019 11:41 am
Location: Austin, Texas

Re: Electrifying my '85 635CSi Euro

Post by mdkohler » Wed Nov 27, 2019 8:24 pm

Quietlion79 wrote:
Wed Nov 27, 2019 4:35 pm
Regenerative braking is the isht. Some people in the forum of my DD, gen1 Honda Insight, have NEVER changed their rear brakes, even after hundreds of thousands of miles.
Indeed it is, I never had to replace the brake pads (front or rear) on my 2009 Prius even after 180k miles!
Marc
Austin, Tx
1985 635CSi Euro

Quietlion79
Posts: 39
Joined: Sat Nov 16, 2019 10:29 pm
Location: Los Angeles

Re: Electrifying my '85 635CSi Euro

Post by Quietlion79 » Thu Nov 28, 2019 3:38 am

Now THAT is impressive. You got SKILLZ, son!!!
1952 Austin Sheerline Limo RHD
1963 Chrysler 300J 413 Dual Quad
1963 Studebaker Avanti R2 4 spd SC
1964 Jensen CV8 Mk2 383 RHD
1970 AMC Rebel Machine 390 4 speed
1981 BMW Euro 635CSI
1989 Chrysler Conquest 2.6 turbo
2001 Honda Insight 5 spd

User avatar
mdkohler
Posts: 65
Joined: Tue Sep 17, 2019 11:41 am
Location: Austin, Texas

Re: Electrifying my '85 635CSi Euro

Post by mdkohler » Mon Jan 27, 2020 3:51 pm

With any EV conversion, one must have three things. A good donor car, buckets of cash (or credit), and loads of patience. So far I have 2 out of 3.
After weeks of planning, I’ve begun ordering the necessary components to convert my 1985 BMW 635CSi into an electric vehicle for commuting to work.
So far I have received the DC-DC converter, charger, electric Air Conditioner compressor, motor & controller. Some of these items may sound familiar to you, some may not.

I thought I would give a brief overview of what these components are and why I chose them.

DC-DC converter:
IMG_4463.jpg
DC-DC converter
IMG_4463.jpg (49.8 KiB) Viewed 1753 times
As the name implies, it is a device that steps down 144VDC down to 12VDC voltage. This provides 12V (up to 70A) throughout the car, running lights, radio, wipers, etc., while drawing its original power from the 144V battery pack. It effectively replaces the alternator which supplies 12V to the car while the car is running.

And since I no longer need a heavy lead acid battery to start the engine, I can replace the current 35lb unit with a small 2lb 12V li-ion battery, as it is only needed to close the main contactor when I turn the key switch, then the DC-DC converter takes over.

I purchased a charger, which takes 120-240VAC input and converts it to 144VDC output (programmable output to the battery pack's charging algorithm). It is rated for 3.3kW, but can be paralleled with another charger to decrease the charging time. That will come in Phase II of the conversion.
It’s air cooled so that I don’t have to worry about running coolant lines to radiators, and has a high ingress protection rating, IP67, such that I can place it under the trunk (where the gas tank used to be) so that it can easily get rid of any heat that it generates.
It automatically adjusts it’s output current based on the input voltage. This way I can charge from any standard wall plug (1.2kW) or any public charging station (up to 6kW).
charger small.PNG
3.3kW charger
charger small.PNG (1.35 MiB) Viewed 1753 times
Because Texas is HOT most of the time, I definitely will need to maintain the air conditioner. I could have used a pulley system to attach the existing A/C compressor to the tail shaft of the motor, but I would have had to keep the motor spinning even when not moving (like an engine that idles). Rather, I chose a high voltage air compressor that will run off of the main battery pack, which I feel is a much more elegant solution and more efficient overall. It’s also about 1/3 smaller and ½ the weight of the original.
IMG_4464.jpg
Electric A/C compressor
IMG_4464.jpg (40.49 KiB) Viewed 1753 times
And finally, we get to the heart of the conversion, the 144V motor and 500A controller, good for ~85kW and 220Nm of torque (0-3800 rpm). It is 9” in diameter, 13” long and weighs 120lbs (55kg). It is also air-cooled for simplicity and can be paralleled with another to double the power of the car. Wallet is placed as a reference for size.
motor and controller 2.jpg
Hyper9 Electric Motor & Controller
motor and controller 2.jpg (1.77 MiB) Viewed 1753 times
The adapter plate is on order which will mate this motor to my 5-speed transmission. I'll upload pictures of it when it is finished. When that is ready it will be time to remove the engine, gas tank, and exhaust system from the car (no turning back after that!).
Marc
Austin, Tx
1985 635CSi Euro

songzunhuang
Bigcoupe supporter
Posts: 928
Joined: Fri Aug 14, 2015 10:04 am
Location: Silicon Valley, CA
Contact:

Re: Electrifying my '85 635CSi Euro

Post by songzunhuang » Mon Jan 27, 2020 6:24 pm

Wow, that some serious stuff.
Did I understand this correctly in that you'll be mating the electric motor to a manual 5 speed tranny?
Almost all electric cars seem to be direct drive (a la Tesla) or come kinda CV, which I don't think exists for a e24. ;)

This will be a very interesting thing to follow. Thanks for being the trail-blazer.
-----
Song Huang
1984 633CSi
Last 7 of VIN: 6997383

User avatar
mdkohler
Posts: 65
Joined: Tue Sep 17, 2019 11:41 am
Location: Austin, Texas

Re: Electrifying my '85 635CSi Euro

Post by mdkohler » Mon Jan 27, 2020 8:59 pm

songzunhuang wrote:
Mon Jan 27, 2020 6:24 pm
Wow, that some serious stuff.
Did I understand this correctly in that you'll be mating the electric motor to a manual 5 speed tranny?
Almost all electric cars seem to be direct drive (a la Tesla) or come kinda CV, which I don't think exists for a e24. ;)

This will be a very interesting thing to follow. Thanks for being the trail-blazer.
True, most EV's use a single ~9:1 gear reduction. I could put mine in 3rd gear and simply drive it like an automatic if I wanted to. But since I have the gears, why not use them for some additional torque down low? The original Tesla Roadster was designed to have a two-speed gearbox, 1st gear to meet desired 0-60 time, and 2nd gear to reach designed top speed. However, by increasing the rpm of the motor and current it could accept, they were able to meet both with a single gear reduction. The motor that I am using only goes to 8k rpm, not 12-14k like the Tesla, so I would need to use 2nd gear for decent 0-40 mph acceleration and 3rd gear as a 40-80 mph highway gear.
Marc
Austin, Tx
1985 635CSi Euro

User avatar
mdkohler
Posts: 65
Joined: Tue Sep 17, 2019 11:41 am
Location: Austin, Texas

Re: Electrifying my '85 635CSi Euro

Post by mdkohler » Tue Jan 28, 2020 4:03 am

Does anyone know what items require vacuum from the engine? In most cars, vacuum helps with brakes, but since the E24 uses the power steering fluid in combination with the brake bomb for assist, it seems that vacuum may only be needed for engine specific items (which I won't need after the conversion). But now I'm wondering if there are vacuum lines that go into the dash to help with the HVAC system and/or vent controls. I can include a 12V vacuum pump with small reservoir to the electric conversion, but I'd rather not if I don't have to.

Can anyone help me out with what vacuum lines exist that are not related to the engine?

(irrelevant fact: my 1985 VW Quantum used vacuum lines to operate the door locks. Very fluid movement compared to the typical electrical thump)
Marc
Austin, Tx
1985 635CSi Euro

User avatar
hornhospital
Bigcoupe supporter
Posts: 2497
Joined: Sun Jul 11, 2010 6:46 pm
Location: Silverhill, AL

Re: Electrifying my '85 635CSi Euro

Post by hornhospital » Tue Jan 28, 2020 7:05 am

The interior temperature sensor mounted above the driver's footwell (on LHD cars) uses engine vacuum to draw air past the sensor.
Ken Kanne
'84 633CSi "Sylvia"; '85 635CSi "Katja";'85 325e "Hazel Ann";'87 325is "Odette"; '93 325is "Elvira"; '95 M3 "Ashlyn"; '95 318is "Bebe"

m6dave
Bigcoupe supporter
Posts: 374
Joined: Sun Oct 04, 2009 10:50 am
Location: New South Wales Australia

Re: Electrifying my '85 635CSi Euro

Post by m6dave » Wed Jan 29, 2020 8:45 am

mdkohler wrote:
Mon Jan 27, 2020 3:51 pm
And finally, we get to the heart of the conversion, the 144V motor and 500A controller, good for ~85kW and 220Nm of torque (0-3800 rpm). It is 9” in diameter, 13” long and weighs 120lbs (55kg). It is also air-cooled for simplicity and can be paralleled with another to double the power of the car. Wallet is placed as a reference for size.
Observation - that wallet is not thick enough to complete this conversion :D

User avatar
sansouci
Bigcoupe supporter
Posts: 1679
Joined: Mon Jul 08, 2013 10:52 pm
Location: New York City

Re: Electrifying my '85 635CSi Euro

Post by sansouci » Sat Feb 01, 2020 2:45 am

I'm reminded of the Patek Phillippe advert: we only hold it in trust for the next generation. So while I admire the science project aspect of this, as a re-do of a piece of rolling art (engine included), this would not be my first choice.

--Ken
Sansouci
84 E24 633Csi Auto, Bronzit/PearlBeige 6997510
93 E32 740il M60 Auto, Alpenweis/Ultramarine
60 528i M30 5-speed Green/Beige (crushed)
71 240Z 4-speed White/Blue (rusty & sold)
65 396 Chevelle 4-speed, Marina Blue/Black (stolen)

User avatar
sansouci
Bigcoupe supporter
Posts: 1679
Joined: Mon Jul 08, 2013 10:52 pm
Location: New York City

Re: Electrifying my '85 635CSi Euro

Post by sansouci » Sat Feb 01, 2020 7:32 pm

PM sent regarding parts for sale
--Ken
Sansouci
84 E24 633Csi Auto, Bronzit/PearlBeige 6997510
93 E32 740il M60 Auto, Alpenweis/Ultramarine
60 528i M30 5-speed Green/Beige (crushed)
71 240Z 4-speed White/Blue (rusty & sold)
65 396 Chevelle 4-speed, Marina Blue/Black (stolen)

User avatar
mdkohler
Posts: 65
Joined: Tue Sep 17, 2019 11:41 am
Location: Austin, Texas

Re: Electrifying my '85 635CSi Euro

Post by mdkohler » Thu Apr 09, 2020 2:31 am

Today was a big day in moving my project forward. As it is with most of us working from home now, I have more time to work on the 635 EV conversion. Although I have loved driving it these past few months, I've acquired all of the electrical components and am ready to start the physical conversion.

After removing the engine, exhaust, and fuel tank, it looks like its ready to go 4wheelin'!
IMG_6248.JPG
500 lbs lighter
IMG_6248.JPG (604.17 KiB) Viewed 1051 times
The engine bay is now empty.
IMG_6260.JPG
Empty bay 1
IMG_6260.JPG (513.06 KiB) Viewed 1051 times
IMG_6261.JPG
Empty bay 2
IMG_6261.JPG (580.5 KiB) Viewed 1051 times
IMG_6263.JPG
Empty bay 3
IMG_6263.JPG (490.12 KiB) Viewed 1051 times
So now I finally have a lot of parts to sell if anyone out there wants to work on their 6.
Marc
Austin, Tx
1985 635CSi Euro

User avatar
mdkohler
Posts: 65
Joined: Tue Sep 17, 2019 11:41 am
Location: Austin, Texas

Re: Electrifying my '85 635CSi Euro

Post by mdkohler » Thu Apr 09, 2020 2:48 am

Engine available for immediate sale:

1985 M30 Euro Spec engine. Approximately 220km on it, perfect temp, 600-700 rpm idle.
IMG_5483.JPG
mileage, temp, idle
IMG_5483.JPG (578.1 KiB) Viewed 1052 times
IMG_6194.JPG
engine in place
IMG_6194.JPG (584.13 KiB) Viewed 1052 times
IMG_5491.JPG
engine half way out
IMG_5491.JPG (597.73 KiB) Viewed 1052 times
IMG_5494.JPG
engine out
IMG_5494.JPG (684.74 KiB) Viewed 1052 times


There are some numbers on the motor:
43013591
34 6E B

(sold)
Last edited by mdkohler on Sat Apr 18, 2020 4:27 am, edited 2 times in total.
Marc
Austin, Tx
1985 635CSi Euro

User avatar
mdkohler
Posts: 65
Joined: Tue Sep 17, 2019 11:41 am
Location: Austin, Texas

Re: Electrifying my '85 635CSi Euro

Post by mdkohler » Thu Apr 09, 2020 2:59 am

Exhaust (with Silverline tips) available for sale. Cut in half. $100 for each half. Front half (headers and CAT) are original, back half (silencer,muffler, tips) is aftermarket.
IMG_5485.JPG
Full Exhaust 1
IMG_5485.JPG (523.97 KiB) Viewed 1051 times
IMG_5486.JPG
Full Exhaust 2
IMG_5486.JPG (395.75 KiB) Viewed 1051 times
IMG_6270.JPG
Near manifold
IMG_6270.JPG (558.78 KiB) Viewed 1051 times
tips.JPG
Silverline tips
tips.JPG (38.3 KiB) Viewed 1051 times
(Sold)

Catalytic Converter is still available.
Last edited by mdkohler on Mon Apr 27, 2020 9:59 pm, edited 3 times in total.
Marc
Austin, Tx
1985 635CSi Euro

User avatar
mdkohler
Posts: 65
Joined: Tue Sep 17, 2019 11:41 am
Location: Austin, Texas

Re: Electrifying my '85 635CSi Euro

Post by mdkohler » Thu Apr 09, 2020 3:05 am

Fuel tank for sale. Looks to be in great shape. No rust. Includes fuel cap and fuel pump/filter.
IMG_6267.JPG
fuel tank 1
IMG_6267.JPG (438.42 KiB) Viewed 1051 times
IMG_6268.JPG
fuel tank side
IMG_6268.JPG (479.89 KiB) Viewed 1051 times
IMG_6266.JPG
fuel tank 2
IMG_6266.JPG (387.2 KiB) Viewed 1051 times
IMG_6253.JPG
fuel pump and filter
IMG_6253.JPG (648.65 KiB) Viewed 1051 times

Fuel sending unit was always accurate.
Also have the fuel lines if interested (although not sure how to ship them).

PM with an offer. Buyer pays for shipping.
Marc
Austin, Tx
1985 635CSi Euro

User avatar
mdkohler
Posts: 65
Joined: Tue Sep 17, 2019 11:41 am
Location: Austin, Texas

Re: Electrifying my '85 635CSi Euro

Post by mdkohler » Thu Apr 09, 2020 3:11 am

I also have an A/C compressor (converted to R134a, including belt) that blows cold ($75), radiator with shroud (with working sensors) and hoses for sale.
IMG_6340.jpg
compressor
IMG_6340.jpg (217.69 KiB) Viewed 930 times
IMG_6255.JPG
radiator
IMG_6255.JPG (788.5 KiB) Viewed 1051 times
IMG_6371.jpg
hoses
IMG_6371.jpg (178.14 KiB) Viewed 930 times
Buyer pays for shipping.
Last edited by mdkohler on Thu Apr 16, 2020 11:47 pm, edited 4 times in total.
Marc
Austin, Tx
1985 635CSi Euro

User avatar
mdkohler
Posts: 65
Joined: Tue Sep 17, 2019 11:41 am
Location: Austin, Texas

Re: Electrifying my '85 635CSi Euro

Post by mdkohler » Thu Apr 09, 2020 3:14 am

I have a power steering pump for sale if needed.
power steering pump.JPG
power steering pump and reservoir
power steering pump.JPG (43.3 KiB) Viewed 1051 times
Make offer. Buyer pays for shipping.
Last edited by mdkohler on Sat Apr 18, 2020 4:26 am, edited 1 time in total.
Marc
Austin, Tx
1985 635CSi Euro

User avatar
jps635
Bigcoupe supporter
Posts: 754
Joined: Sat Feb 27, 2010 10:50 pm
Location: NZ

Re: Electrifying my '85 635CSi Euro

Post by jps635 » Thu Apr 09, 2020 5:55 am

This is quite interesting and I admire your courage and technical knowledge. However, couple of questions:
- Do I understand correctly, you are converting from 160 KW - 310 off Nm, to 85 and 220. What's the overall power to weight ratio conversion by comparison
- What considerations around battery heat management. Excuse my ignorance if this is not an issue for your application/ spec.
'85 635csi JPS (RA2-66)

User avatar
86_6series
Bigcoupe supporter
Posts: 560
Joined: Mon Apr 02, 2007 10:08 pm
Location: West Nyack, NY

Re: Electrifying my '85 635CSi Euro

Post by 86_6series » Thu Apr 09, 2020 11:32 am

PM sent about oil cooler.

User avatar
mdkohler
Posts: 65
Joined: Tue Sep 17, 2019 11:41 am
Location: Austin, Texas

Re: Electrifying my '85 635CSi Euro

Post by mdkohler » Thu Apr 09, 2020 3:33 pm

jps635 wrote:
Thu Apr 09, 2020 5:55 am
This is quite interesting and I admire your courage and technical knowledge. However, couple of questions:
- Do I understand correctly, you are converting from 160 KW - 310 off Nm, to 85 and 220. What's the overall power to weight ratio conversion by comparison
- What considerations around battery heat management. Excuse my ignorance if this is not an issue for your application/ spec.
Phase 1 will use one motor (85kW and 220Nm), while I work out all the issues. Phase two will use two motors (170kW and 440Nm) in parallel. I suspect that when the conversion in finished, I will have added about 500 lbs (227 kgs) to the overall weight of the car, but still keeping within gross vehicle weight. I imagine that it will feel like I have 3 passengers with me, but with the extra torque, it may even out so that it performs as well as when new. It should make a fun city car (0-45mph).
IMG_5519a.jpg
Dual motors one side
IMG_5519a.jpg (943.31 KiB) Viewed 1024 times
IMG_5517a.jpg
Dual motor other side
IMG_5517a.jpg (930.44 KiB) Viewed 1024 times
As for battery heat management, I won't have any. I only have a ~25kWh pack (70-90 miles of range) so will not be on the road long enough to need it. Just like the gen 1 Nissan Leaf. For my application, I plan to commute to work (22 miles), then plug in. Return home, repeat. If the batteries get hot (which they will in Texas), or cold (reducing range), that is okay with me.
Marc
Austin, Tx
1985 635CSi Euro

User avatar
mdkohler
Posts: 65
Joined: Tue Sep 17, 2019 11:41 am
Location: Austin, Texas

Re: Electrifying my '85 635CSi Euro

Post by mdkohler » Thu Apr 09, 2020 3:40 pm

86_6series wrote:
Thu Apr 09, 2020 11:32 am
PM sent about oil cooler.
Strange, nothing came through. Go ahead and send it to my home email
contact.JPG
contact
contact.JPG (9.24 KiB) Viewed 1023 times
Marc
Austin, Tx
1985 635CSi Euro

bpoliakoff
Bigcoupe supporter
Posts: 2853
Joined: Thu Sep 28, 2006 9:28 pm
Location: scottsdale, arizona
Contact:

Re: Electrifying my '85 635CSi Euro

Post by bpoliakoff » Thu Apr 09, 2020 11:52 pm

I recently saw a highly modified XK 129 jag. The A/C was an electric compressor in the fender well with a small condenser An interesting thought for you to possibly simplify one of the systems
81 Euro 635 M90 with motronic. Currently under a complete nut and bolt restoration. Pictures at
flickr.com/photos/bertsphotos.

User avatar
mdkohler
Posts: 65
Joined: Tue Sep 17, 2019 11:41 am
Location: Austin, Texas

Re: Electrifying my '85 635CSi Euro

Post by mdkohler » Fri Apr 10, 2020 12:35 am

bpoliakoff wrote:
Thu Apr 09, 2020 11:52 pm
I recently saw a highly modified XK 129 jag. The A/C was an electric compressor in the fender well with a small condenser An interesting thought for you to possibly simplify one of the systems
Thanks bpoliakoff, I plan to use an electric compressor for the A/C. Scroll up the page to the 5th entry to see a picture. It's smaller and lighter than the original.
Marc
Austin, Tx
1985 635CSi Euro

bpoliakoff
Bigcoupe supporter
Posts: 2853
Joined: Thu Sep 28, 2006 9:28 pm
Location: scottsdale, arizona
Contact:

Re: Electrifying my '85 635CSi Euro

Post by bpoliakoff » Fri Apr 10, 2020 12:52 am

Missed that. If I wasn't doing an accurate resto I think that would be the way to go
81 Euro 635 M90 with motronic. Currently under a complete nut and bolt restoration. Pictures at
flickr.com/photos/bertsphotos.

Post Reply

Who is online

Users browsing this forum: No registered users and 2 guests