Aussie students create Volkswagen Kombi EV

Meet #SCUKombi, the all-electric Volkswagen Kombi created by students – and graduates – from Southern Cross University’s Lismore campus in northern NSW.

Combining zero-emissions EV technology with the old-school charm of a classic VW Kombi, the electric camper was produced in collaboration with NSW government and lead contractor EV Machina.

Conversion of the uni’s iconic promotional vehicle centred on the fitment of an 88kW AC Synchronous Reluctance Internal Permanent Magnet (SRIPM) electric motor.

The US-sourced Netgain Hyper9 e-motor is powered by a 53kWh water-cooled lithium battery pack with cell-level battery monitoring system and a 6.6kW onboard AC charging system.

Evenly split in fabricated boxes front (between the front seats) and rear (in the engine bay) to maintain the original vehicle’s weight balance, the battery pack comprises 10 individual Tesla batteries, each weighing 25kg for a total weight of 250kg. Yet total weight is slightly less than the original Kombi’s.

Coupled with a custom billet aluminium transmission adapter plate attached to the overhauled original transmission, the EV powertrain delivers a highway cruising speed of 110km/h and a target range of 220km – enough to drive between the university’s three east-coast campuses in Lismore, Coffs Harbour and the Gold Coast.

Other upgrades included an electric power-assisted disc brake system with an additional motor for regenerative braking, a speed-variable custom electric power steering system and an internet-connected dashboard display with Android operating system and OBD connection to motor and battery information.

SCU said the biggest task was removing the rear-mounted boxer petrol engine that had been in place for 43 years and replacing it with the AC motor, inverter and batteries while still retaining the vintage look and feel of the Kombi.

That included fabricating a new charge socket cover to replace the old petrol cap and preserve the vintage exterior look, which was finished off with aluminium enamel and several clear enamel top coats.

Other tech details include a 4.5kg flywheel that weighs about a third of the original, an upgraded high-torque clutch kit, a new stick-shifter to replace the flimsy original and an LED-illuminated charger, cooling plates and cooling fluid chamber that add disco vibes to the engine bay.

Described as one of Australia’s most ambitious EV prototypes and an electric billboard for clean transport technology, the #SCUKombi is designed to showcase the skills of SCU’s Faculty of Science and Engineering.

It claims to be a leader in the field of environmental engineering and sustainable energy, citing clean energy solutions such as harvesting biosolids for energy from wastewater and its mobile Sunflower that can power music festivals.

Led by contractor and Southern Cross graduate Andy Naughton, the electric Kombi project took several months to complete with help from students including Max den Exter and the support of SCU’s engineering department.

Naughton, who studied Environmental Science at SCU, won a renewable energy project competition run through the Enterprise Lab at Southern Cross and his business EV Machina was awarded the contract to convert the Kombi.

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Full story published as A long-range vintage electric vehicle for regional Australia on scu.edu.au