balefire

Very awesome.
Reminds me of the electric 944 dragster featured on Top Gear USA.
Once complete, are you planning for this electric 996 to be a DD or a weekend car?
How much would CHAdeMO add?

rustymon

Daily driver all the way, hopefully one with a little extra quotient of fun added in... instant 400 ft/lbs of torque anyone? (at least, that's the plan!)

We looked into CHAdeMO, and about 8 months ago there weren't any real DIY kits available yet, but we set up some wiring for one anyway... I hope to add that in the future. As this is part of the build relies on professional assistance, I was quoted about 1K or so after all parts and labor, with the unit being placed behind the licence plate which would pop-up.

rustymon

OK, so more parts in... getting closer...
The green box added to the trunk lid is the speed controller's HairBall.
This is it's brain and its low voltage/current wiring interface to communicate with the rest of the car. High Voltage/Current connections are on the big green Zilla mounted below, at left. Note the water tubing... this Zilla motor controller is water cooled using the stock radiators!


So, why use the trunk lid for installing all these parts? To quote Kirk from ShiftEV, the engineer behind all of this, "it's working out very sweet for this constrained space, is highly functional and a true eye candy design!" He pointed out that there were already 12 wire connections in the stock trunk lid for fan, light, spoiler motors, etc. and there are other 911 trunk lids with coolers and more built into them. So there's a second gas support strut partly in the design for such weighty options. We're approximately doubling the wire count to the trunk lid, but it just makes sense when all factors are considered. They'll be properly anchored and have minimal movement. The new wires will all be routed through one, possibly two tubes, seen in the center. Some are strung temporarily for now. But it will be tidy and neat when finished.

A second gas shock is on order, for the left side of your trunk to make sure it holds up its weight and never slams shut. The right strut is removed in these pics,but you can see the upper and lower ***** it connects to. We just have to drill and tap a hole on the left upper tab for the new ball to attach. The lower left ball location has a threaded hole in the stock body.


The other part recently mounted is the factory AC pump, which is bolted down. The aluminum Air Conditioner pump "tube" that I'm pointing at is a stock part. It sticks out toward the battery box, and prevents us from sliding the pump far-enough to align its "driven pulley" to the "drive pulley" on the motor. When the car is running, we'll drive it to an Air Conditioning shop and have it replaced with a tube that's out of the way. We could try and bend it, but it could burst since it's still pressurized. Just one more little detail to fix up...

balefire

Very exciting.
Like the water cooled aspect.
Bought my wife a Tesla recently and loving it.
But I would really love a 4 seater manual tranny electric Porsche as my daily driver!
Guess I will live vicariously through you and this thread...
Thanks!

rustymon

And I shall live vicariously through you, the one already driving around in an electric car!

In other news, not that anyone should dare one-up me on this project, but there's a pretty sweet 2005 with blown engine on-ebay now... who wants to have their own electric 911? http://r.ebay.com/jA1qeU

Imo000

Are you sure those parts on the engine lid are meant for outdoor use? They don't look to me that they are protected from the elements at all. Those cooling fans look like the ones used in PC power supplies.

NineEreven

Any fail safe in case of a wreck to disconnect high voltage systems?

alpine003

Funny I was actually thinking about this the other day. Any EE can easily rig up an accelerometer to an Arduino board and relay to achieve a simple yet effective safety cutoff in case of an accident.

rustymon

Thanks for the questions! Yes, although they almost look like a power supply you pulled out of your computer, they are rated for outdoor use... but we do not want to get them wet. The entire lid has been sealed and these babies will stay dry.

You bet - there are actually multiple levels of safety layered in, and like everything else in the build, I think we've gone above and beyond what is typical. First, there is an inertia switch built into the wiring system. This safety switch senses shock or vibration and is installed so if I were to get into an accident it would shut everything down to help prevent further damage or harm. Secondly, there is a large battery disconnect pull handle mounted below the rear bumper, made out of bright orange plastic. A first responder can simply pull this and it will disconnect all batteries. This is also helpful for quickly disconnecting things for service etc. We may also add a big red KILL button somewhere else, but not sure yet. Beyond that, the Battery Management System (BMS) will have some fail-safe tolerances built in that will allow the software to cut things off if extreme pack output is registered, etc.

I think I have some photos of the safety disconnect... I'll try to post those later.

Imo000

The rest of the engine compartment is sealed from the elements too?

rustymon

Yes - we are taking a great deal of precaution to ensure everything stays dry... of course, here in rainy Oregon, I've got no choice but to drive in the rain! This is certainly intended to be an all-weather vehicle, and we're doing what we can to ensure longevity of the build. Each battery box is sealed individually - the polycarbonate tops are sealed along all edges. We've only built a bit of custom water shrouding around the wheel wells to prevent splashing in. Much of the underside will rely on the plastic underbody panels. We shall see how it does... we plan on running with some remote cameras in the engine bay when we test to be sure!

rustymon

Here are photos of the easy "first responder" disconnect that was taken when it was fabricated... it is on the left side of the left saddle-bag battery box in the back. I can't find my photo of it when installed...

Imo000

Very nice!

GuardsTurbo

Awesome job op, but it will be a truly sad day for me when a Porsche drives by me and I hear nothing but tires on the road

5CHN3LL

Me too - I'll definitely get misty-eyed when I see one of these roll by in electric-only mode.