Smart Fortwo EV conversion

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Evanesence2

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Building a crazy electric Smart Fortwo! I dropped the dream of getting Mercedes for this budget-friendly plan. Got myself a lightweight 2005 Smart as the base and I'm planning a good battery (Headway 10Ah, 48S-8P), a Kelly KDHD 156V 1000A controller, and a modified forklift motor. The stock transmission is toast, so I'm thinking between a custom fixed-ratio transfer case with LSD or adapting a FWD LSD transmission using Honda or VW with fixed ratio and using its reverse. Also need help figuring out a faster 120V charger for the Mini BMS Any advice on the motor, BMS, or voltage, is 154V good? or this is a recipe for disaster?
 
This sounds like an incredible project! That battery pack configuration looks solid, and using a modified forklift motor with a high-amp controller could make for a surprisingly powerful build. For the drivetrain, I’d lean toward the custom fixed-ratio transfer case with LSD. Simpler, lighter, and avoids the complexities of adapting a FWD transmission. The voltage should be fine. Just make sure your motor and BMS can handle the peak loads. For faster charging, you might want to look into OpenEVSE or similar DIY chargers that support higher amps.
 

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