Raising Car for Off-Road Crawling or Rally

fell man

Well-known member
Joined
Oct 31, 2008
Location
Sierra Eastside
TDI
2001 Golf 5m, 2003 Jetta Wagon
So this BUD's for you Manny,

Pics of my ride in one of my favorite spots on the planet. Can you guess where? Great thing about a lift. Park where ever you want.
 

fell man

Well-known member
Joined
Oct 31, 2008
Location
Sierra Eastside
TDI
2001 Golf 5m, 2003 Jetta Wagon
So not a great shot of my lift but visually appealing. For reference that is a 4'x6' metolius crash pad in the background and the car is sitting on a cambered mound so you can't see the true lift height. I'll post some more when I upload more, this was my first test for pictures and I'm at work right now so I'll get some this weekend while out pebble wrestlin'.
 

hevster1

Vendor
Joined
Nov 14, 2005
Location
Columbia NJ
TDI
98 NB
I would like to make a suggestion. Look around for a Toyota Tercel 4wd wagon of about 84 vintage. They are still out there if you look hard enough. You can swap in a TDI or run the stock gas engine (40Mpg). Parts are cheap and you can lift them more if you like.

An older Toyota 4x4 pickup or 4 runner is also a good choice for a TDI swap. They are far stronger and will go much further off road with no issues. Many TDI swaps have already been performed to these.

Regardless, even if you do decide to move forward with doing this to a TDI, I wish you good luck.
 

coalminer16

Top Post Dawg
Joined
Dec 11, 2008
Location
Central Wisconsin
TDI
Golf 2004
Only thing with my brother doing the air bags is he doesn't off road with his TDI. He has a blazer and a few other trucks and a couple cummins engines siting around so there isn't a need to go in the back country with his TDI. But I will tell you what he thinks and how he mounts the air hose. I wouldn't mind the Toyota with a tdi in it but I am out of room for more cars for now. I can only afford to have 3 for now. Maybe in the future I will do a TDI into a toyota.
 

manual_tranny

Smyth Performance- Intern
Joined
Jan 5, 2010
Location
New Bedford, MA
TDI
2001 Golf @182K; 2000 Jetta @290K
fell man said:
So this BUD's for you Manny,
Pics of my ride in one of my favorite spots on the planet. Can you guess where? Great thing about a lift. Park where ever you want.
This is gorgeous. I wish I could guess for sure, but I would like to see a little more of the landscape. Joshua tree? I wish I could live there. If I get my way, I will. Those tires do fill up the wheel wells...! As soon as I can get on another good trip I'll get some pictures of my crashpad and cooler on the top of my car. I have a Flashed crash pad that I believe is 4x6, and about 4" thick. Biggest I could get! If you ever are in Illinois, there is a really beautiful gym I am at all the time, Upper Limits. I set some of the routes, many 65ft routes inside and two 110ft routes outside the last 2 years.
coalminer16 said:
Only thing with my brother doing the air bags is he doesn't off road with his TDI. He has a blazer and a few other trucks and a couple cummins engines siting around so there isn't a need to go in the back country with his TDI. But I will tell you what he thinks and how he mounts the air hose. I wouldn't mind the Toyota with a tdi in it but I am out of room for more cars for now. I can only afford to have 3 for now. Maybe in the future I will do a TDI into a toyota.
It's not a big deal if your brother doesn't off-road test the bags, as I don't plan on driving terribly fast off-road. While I'm definitely still going forward on my off-road MKIV project, I have another idea that has been kicking around.
I wouldn't mind doing a second project- replacing my F350 with a 4runner 4x4 ALH. I'd like to go big with the intercooler and radiator, get enough guages to be sure the engine is staying cool. I can't help but wonder if the 4runner could even get away with some towing with an extra-big radiator and intercooler. I'm determined to become proficient at maintaining the ALH, and asking for 200hp+ or so on a regular basis would eventually give me a good opportunity to rebuild one, learn what fails, and try to find improved parts or someone with the machining tools who will make them with me.
 
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fell man

Well-known member
Joined
Oct 31, 2008
Location
Sierra Eastside
TDI
2001 Golf 5m, 2003 Jetta Wagon
Bishop, CA. The Buttermilks. Land of the hard lines. That's Grandpa and Grandma Peabody. The large ones that are bottom right(Can you say Evilution(v12!)).I did just get back from J Tree(good moderate bouldering, little tall) and took some good shots of the car and climbing but somehow didn't save the car shots. But back to the topic. That is why I think the 26.8 wheels are about as much as you can go before cutting/rolling the fenders.Just put my studs back on for this round of storms. I'll get some pics this week. Manny I'll see what's going on next month and see what the road trip is looking like before I start school. Thinking of flyin' out that way to pick up a B4 passat wagon for the lady, so I'll keep you posted if I'm out that way.
 

Frankencar

Veteran Member
Joined
May 15, 2007
Location
Dixon, California
TDI
1991 GTI +TDI, Lifted 98 NB TDI, Corrado TDI Swap, 15 Golf TDI, a dozen TDI motors etc...
manual_tranny said:
It's not a big deal if your brother doesn't off-road test the bags, as I don't plan on driving terribly fast off-road. While I'm definitely still going forward on my off-road MKIV project, I have another idea that has been kicking around.
My Dad ran the bags on a 4X4 Toyota Van and it saw many load variations and a ton of off roading. the bags have held up for over 15 years now. :)
 

fell man

Well-known member
Joined
Oct 31, 2008
Location
Sierra Eastside
TDI
2001 Golf 5m, 2003 Jetta Wagon
Frankencar, I have one of those toyota vans(4x4, 5sp). Any thoughts of putting a tdi in there? I've thought of a 1Z or a suped up 1.6td(mechanical injection). That would be the ultimate run around rig. For me that is. Also, I know alot of guys on the van site run the airbags with success. I ran some rubber spacers from kragens to lift my rear 2", then the cranked the torsion bars up front. So, I can't say for sure about airbags. Though if I start towing frequently with the golf I'll definately go that way.
 

manual_tranny

Smyth Performance- Intern
Joined
Jan 5, 2010
Location
New Bedford, MA
TDI
2001 Golf @182K; 2000 Jetta @290K
fell man said:
Frankencar, I have one of those toyota vans(4x4, 5sp). Any thoughts of putting a tdi in there? I've thought of a 1Z or a suped up 1.6td(mechanical injection). That would be the ultimate run around rig. For me that is. Also, I know alot of guys on the van site run the airbags with success. I ran some rubber spacers from kragens to lift my rear 2", then the cranked the torsion bars up front. So, I can't say for sure about airbags. Though if I start towing frequently with the golf I'll definately go that way.
Droooool....
 

slojoe

Veteran Member
Joined
Mar 1, 2005
Location
me
TDI
02 Golf
manual_tranny said:
How are the 215/75s? ...do you notice the increased mass of the tire? Do you think these tires would do better if you had a 1" lift? (instead of the 2") I'm sure Kitsune would be interested in hearing about road noise, too... thanks in advance!

Oh... and what are the tires? ha...
Tires are Michelin Destiny. I think they have since changed the name though. I haven't noticed anything to do with "increased mass," other than "decreased mpg," about 3 less. They would probably not fit with 1" lift, I got the car lifted then went to the tire shop and mounted the tallest tire that would fit. No increase in road noise. I think they are considered minivan/SUV tires, more for onroad than for off, I have separate tires for winter use. Still the Michelins are tough, no punctures in 65k miles, no cracking, no cupping, still true.
 

Frankencar

Veteran Member
Joined
May 15, 2007
Location
Dixon, California
TDI
1991 GTI +TDI, Lifted 98 NB TDI, Corrado TDI Swap, 15 Golf TDI, a dozen TDI motors etc...
fell man said:
Frankencar, I have one of those toyota vans(4x4, 5sp). Any thoughts of putting a tdi in there? I've thought of a 1Z or a suped up 1.6td(mechanical injection). That would be the ultimate run around rig. For me that is. Also, I know alot of guys on the van site run the airbags with success. I ran some rubber spacers from kragens to lift my rear 2", then the cranked the torsion bars up front. So, I can't say for sure about airbags. Though if I start towing frequently with the golf I'll definately go that way.

A diesel wold be nice. the Toyota diesel that cam in them elsewhere would be simpler. I would rather have a Syncro Westy TDI Van with front and rear lockers though. :D
 

rockyrunner99

Veteran Member
Joined
Aug 20, 2009
Location
Grand Rapids, Mi
TDI
99.5 Golf
I have to admit I did not read all the pages of this thread, so if this has been suggested all ready, I am sorry.

I agree with the poster on the 1st page that the money you are investing into your jetta could easily pay for your fuel for several years. I have been thinking about this too, cause I mountain bike, and drive down some nasty forest roads to get to trail heads. They don't sound as bad as the terrain you are dealing with, but worth having a higher clearance vehicle. My thoughts, or dream for the ultimate off road and everyday driver. If I had an unlimited budget, get a new jeep wrangler, one with a 6 speed manual. swap in a TDI. Do a couple engine mods. I am sure you could be getting nearly 40 mpg at around 50mph, though it would drop quickly with speed. I am not into off roading much, but a stock jeep wrangler, I know could handle anything I would ever want to get through.

THats just my $.02
 

manual_tranny

Smyth Performance- Intern
Joined
Jan 5, 2010
Location
New Bedford, MA
TDI
2001 Golf @182K; 2000 Jetta @290K


This guy found the thread after he lost an argument to me about how his chainsaw motor (2-stroke motorcycle) 250cc was "faster" than most 750ccs... (newsflash, it's not) He's the same loser who has been throwing insults at the moderators and respected mechanics in the "I want smoke" thread... What do we have to do to get him to stop trolling?
 
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manual_tranny

Smyth Performance- Intern
Joined
Jan 5, 2010
Location
New Bedford, MA
TDI
2001 Golf @182K; 2000 Jetta @290K
rockyrunner99 said:
I have to admit I did not read all the pages of this thread, so if this has been suggested all ready, I am sorry.

I agree with the poster on the 1st page that the money you are investing into your jetta could easily pay for your fuel for several years. I have been thinking about this too, cause I mountain bike, and drive down some nasty forest roads to get to trail heads. They don't sound as bad as the terrain you are dealing with, but worth having a higher clearance vehicle. My thoughts, or dream for the ultimate off road and everyday driver. If I had an unlimited budget, get a new jeep wrangler, one with a 6 speed manual. swap in a TDI. Do a couple engine mods. I am sure you could be getting nearly 40 mpg at around 50mph, though it would drop quickly with speed. I am not into off roading much, but a stock jeep wrangler, I know could handle anything I would ever want to get through.

THats just my $.02
If you're really interested, read the thread. It won't take nearly as long as you think! There are lots of valuable details... I welcome new-comers to the thread, but I want them to be up to speed. There is a lot of information here considering how esoteric this raise is.

I want you to have the MKIV off-road reading experience that I had... it has helped me make well-informed plans. I started the thread a couple months before I would start my project, hoping I would get even a small amount of attention... and it has quickly become popular!! I guess I'm not the only one with a 50mpg machine that wants to take it off the pavement.

Also, it really doesn't matter much what motor you have in your vehicle once you have enormous tires. You'll get poor milage in a Jeep even if you have an ALH motor.
 

manual_tranny

Smyth Performance- Intern
Joined
Jan 5, 2010
Location
New Bedford, MA
TDI
2001 Golf @182K; 2000 Jetta @290K
Aquaticmind said:
Any thoughts on adapter from VW diesels to truck trannys? I have an Isuzu Amigo that I use to 4wheel alot that has a blown head gasket, and I keep having this idea of a TDI Amigo.
So.. where do I find a VW diesel adapter to a truck tranny?
Frankencar said:
Run a Toyota Transmission.
Isuzu/Acme/Toyota/VW/TDI/Amigo? Sounds like a pretty serious project, but if you could make it work...
 
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sweetjeep

Veteran Member
Joined
May 16, 2005
Location
North Central, MA
TDI
2002 Jetta
manual_tranny said:
I have a fantasy... that somehow electric drive could be hooked up to the rear wheels, and that the parking brake could be fitted to work as a regenerative braking command for the motor(s), that the electricity would be quickly and efficiently contained in two car-battery-sized ultracapacitor banks that could push as much power as the electric motor(s) could safely take. I imagine the hardest part would be engineering the part that would work as a regenerative brake and a centrifugal clutch for the rear wheels, while the second hardest design would be rear axles to centrifugal clutch. Control mechanisms would be available and since I wouldn't care what the prototype looked like, only a few parts and some fabrication would be expensive. I would be happy if my fully-charged ultra-capacitors had only 400-800ft of acceleration available, they would mostly function as a brake saving and fuel saving device, that as a side benefit, would allow manual control of fwd, rwd, and 4wd.
This sort of thing would be really handy when it came to getting up slippery slopes, getting un-stuck in deep snow, eliminating front brake wear (depending on driver use of rear motor as brake), and hybrid drive system without a computer telling you how to use it, how good you are at driving it, etc. The weight over the rear axles would increase, but having available drive back there would help things.
Hey ManualT: I just found this thread last night. I have been slowly working toward a lifted Jetta also.

I happen to be in the camp that off roading a VW is a terrible idea. But I am also a Jeep guy (and strongly disagree with your opinion on Jeep reliability, mine have been pretty bulletproof, but that's another discussion!) and I also understand having to work with what you have.

Specifically toward your electric AWD system. That's ironically on my list of to-dos. I work at a robotics company so I have a pretty reasonable idea about the workings of electric motors and the like. I also happen to have an Audi A4 so I have a vague idea how VW does their AWD bits, and as a Jeep guy so I have a penchant to f* with things.

My plan is to drop the rear end of a TT into my Jetta. It SHOULD bolt in pretty easily. Should. Plus I'll get to keep the same wheels and I think the brakes will get slightly larger in the rear. I run GTI bits now, but they are the same, just red (in the rear). For the record, it's never, ever a good idea to shrink your brakes. I'd stick with the 15" wheels and if you want to run bigger rubber, drop a spacer on and space the wheel out a bit to fit the larger rubber. I found my stock brakes adequate. I put on a set of GTI brakes, and measurably they are not that much bigger, but the stopping improvement was pretty serious. Brakes are more than just about 1 time clamping power. Especially don't forget all the extra stuff/weight and what not you have added to your car (coolers, racks, people, whatever).

As to the motor. That's a tough call, there is a lot of suitable stuff on the market and in junkyards. That's on you.

Batteries. No capacitors. That's not what you want. You WANT good old fashioned Lead Acid batteries. They'll be bulky and heavy but you can get better/smaller batteries if you so desire. Optimas, Braille whoemever makes nice lightweight batteries for a price. You don't want capacitors.

You have WILDLY over thought the regen. An electric motor does 2 things. It takes power and causes the armature to spin, or you spin the armature and the motor generates electricity. (yes, very simplified, but basically true) If you're smart, you'll spend the money on a GOOD controller for the motor. You'll then have a throttle which you can vary the power applied and the controller will automagically recharge the batteries for you. And you're done. Ta-daa.

If you want to be even simplier.. you can hook up a contactor, it's like a relay but works in the exact opposite. You turn it on and power is dumped to the motor, when the power is depleted from the batteries, the motors turn (from the wheels) and charge the batteries back up. Or you can slightly modify the system so the batteries are charged when.. blah blah blah, it's too much to type but pretty simple.

Point is, the hardest part is getting and fitting the rear part of the AWD system. But, everything you need is on a shelf somewhere waiting for you to pick it.
 
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manual_tranny

Smyth Performance- Intern
Joined
Jan 5, 2010
Location
New Bedford, MA
TDI
2001 Golf @182K; 2000 Jetta @290K
sweetjeep said:
Hey ManualT: I just found this thread last night. I have been slowly working toward a lifted Jetta also.

I happen to be in the camp that off roading a VW is a terrible idea. But I am also a Jeep guy (and strongly disagree with your opinion on Jeep reliability, mine have been pretty bulletproof, but that's another discussion!) and I also understand having to work with what you have.
Thanks for your ideas! I am hoping that you stick around to tell us all why you feel that it is a terrible idea to off-road a VW. I don't mind opinions, but I like them a lot more when they are presented with good experience or data.
sweetjeep said:
Specifically toward your electric AWD system. That's ironically on my list of to-dos. I work at a robotics company so I have a pretty reasonable idea about the workings of electric motors and the like. I also happen to have an Audi A4 so I have a vague idea how VW does their AWD bits, and as a Jeep guy so I have a penchant to f* with things.

My plan is to drop the rear end of a TT into my Jetta. It SHOULD bolt in pretty easily. Should. Plus I'll get to keep the same wheels and I think the brakes will get slightly larger in the rear. I run GTI bits now, but they are the same, just red (in the rear). For the record, it's never, ever a good idea to shrink your brakes. I'd stick with the 15" wheels and if you want to run bigger rubber, drop a spacer on and space the wheel out a bit to fit the larger rubber. I found my stock brakes adequate. I put on a set of GTI brakes, and measurably they are not that much bigger, but the stopping improvement was pretty serious. Brakes are more than just about 1 time clamping power. Especially don't forget all the extra stuff/weight and what not you have added to your car (coolers, racks, people, whatever).
First of all, awesome that you have the same idea.

I still have the original brakes on my car- pads, rotors, etc. at 126K miles. They have lots and lots of life left, they work like new. I don't really use them unless there is an emergency. I pull into parking spaces and shut the key off and let it idle into place. We have different philosophies on brakes and brake use. I own an SVX, so I am already very familiar with EXACTLY what happens when you have undersized brakes on a heavy car. ;) I don't go 100-0mph in my Golf, so brake fade isn't going to come up any time soon. Brakes in my Golf really are about 1 time stopping power, because they really are for emergency use when I drive. Anyway, it's a moot point because I decided not to spend the money on smaller brakes/wheels.

sweetjeep said:
As to the motor. That's a tough call, there is a lot of suitable stuff on the market and in junkyards. That's on you.

Batteries. No capacitors. That's not what you want. You WANT good old fashioned Lead Acid batteries. They'll be bulky and heavy but you can get better/smaller batteries if you so desire. Optimas, Braille whoemever makes nice lightweight batteries for a price. You don't want capacitors.
Actually, if I took this modification seriously, I would want both batteries and ultracapacitors. Capacitors save batteries a lot of abuse and extend their life. There are orders for ultracaps coming from europe for autos and from China for busses. Ultracapacitors outlast batteries, they take a charge faster, and they discharge electricity faster - all without wearing out, (well, they do but really slowly). I am not kidding myself that I am teaching you anything here, I believe that if you work with robotics, you already know this and more, so I'm hoping that you will share the "more" part with me, WHY wouldn't I want ultracapacitors?
sweetjeep said:
You have WILDLY over thought the regen. An electric motor does 2 things. It takes power and causes the armature to spin, or you spin the armature and the motor generates electricity. (yes, very simplified, but basically true) If you're smart, you'll spend the money on a GOOD controller for the motor. You'll then have a throttle which you can vary the power applied and the controller will automagically recharge the batteries for you. And you're done. Ta-daa.

If you want to be even simplier.. you can hook up a contactor, it's like a relay but works in the exact opposite. You turn it on and power is dumped to the motor, when the power is depleted from the batteries, the motors turn (from the wheels) and charge the batteries back up. Or you can slightly modify the system so the batteries are charged when.. blah blah blah, it's too much to type but pretty simple.
I don't think it's blah blah blah, I'm getting pretty excited to hear that this is not as much of a fantasy as I thought. If I could get this done to my car, I could offer the conversion to everyone who owns a MK4. This is something I believe a whole lotta people would be interested in if it were available!! And I didn't really over-think the regen brakes, I just started to piece out ideas as I was typing that post. I was pretty darn sure that there was no way in hell anybody was going to respond to it with anything more than "yeah, that would be nice"...
sweetjeep said:
Point is, the hardest part is getting and fitting the rear part of the AWD system. But, everything you need is on a shelf somewhere waiting for you to pick it.
mmmmmmrrrrglllllllllppppphhhh...... drooooooooll.....:D

I hope I don't seem too argumentative, I really just want to hear why you hold these opinions... you are probably a heck of a lot better educated about this stuff than me!!! Thanks for the info, and thanks in advance for a reply!!

Mike
 
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sweetjeep

Veteran Member
Joined
May 16, 2005
Location
North Central, MA
TDI
2002 Jetta
No argument assumed! ;)

I've been part of the site for years and years.. don't PLAN to leave anytime soon. I've been known to get into a fight or 2 and lose some of them.. but.. hey.. such is life!

A new age Jetta/Golf platform vehicle is a bad idea because it's simply not designed for off roading. I don't truly know what your idea of off-roading is, but mine is generally pretty serious. But with 90% of unibody cars they are not boxed up and welded together in a way that promotes longevity in this use. You get massive body flex when 2 or 3 wheels off the ground. This slowly grinds away at seams and welds and glue joints. With out the frame to hold the body and take the stresses it'll wear out the body quicker than you might like. In short order it's likely to start getting creaky and rattly. A pretty easy fix would be a subframe. But that's a preventative measure more than a fix-it-all.

Adding a roll cage and "attaching it" to the subframe.. also very helpful, but now you're eating away at the space available in the car.

The underbody of the car is very "soft" and doesn't take to impacts well. My car is MOSTLY an on road car and the underbody is chewed to sheet. If you munge the rocker on your Jetta.. you're in a world of hurt, for example.

I gotta head to bed.. but I'll pick this up when I get a chance.
 

TdiRacing

Vendor
Joined
Aug 19, 2003
Location
Baltimore, MD
TDI
2006 Jetta TDI Cup
We raced a 200 Golf TDI for 6 years in Pro Rally. It is not difficult to do. Get good shocks and springs made and that is all you really need plus a good strong skid plate if you are seriously going off road. We built a frame of roll bar tubing under the front then added a thick aluminum plate over it. Could take a beating. If you want info on this, please contact me and I can help you out. We actually did it with success.
 

manual_tranny

Smyth Performance- Intern
Joined
Jan 5, 2010
Location
New Bedford, MA
TDI
2001 Golf @182K; 2000 Jetta @290K
TdiRacing said:
We raced a 200 Golf TDI for 6 years in Pro Rally. It is not difficult to do. Get good shocks and springs made and that is all you really need plus a good strong skid plate if you are seriously going off road. We built a frame of roll bar tubing under the front then added a thick aluminum plate over it. Could take a beating. If you want info on this, please contact me and I can help you out. We actually did it with success.
Sweet... I know it's been done with success, but I could only find a European video, in German, and I couldn't even understand what modifications they did. (I will be meeting a German friend soon and I will demand that she watch this video and translate for me:D ) I will be in touch soon, and I will share as much information in this thread as I can.
 

Frankencar

Veteran Member
Joined
May 15, 2007
Location
Dixon, California
TDI
1991 GTI +TDI, Lifted 98 NB TDI, Corrado TDI Swap, 15 Golf TDI, a dozen TDI motors etc...
sweetjeep said:
No argument assumed! ;) ...
You get massive body flex when 2 or 3 wheels off the ground...
2 or 3 wheels off the ground huh? how about 4!?! :D you must have been looking at my pics on Vortex! :eek:
 

sweetjeep

Veteran Member
Joined
May 16, 2005
Location
North Central, MA
TDI
2002 Jetta
Frankencar said:
2 or 3 wheels off the ground huh? how about 4!?! :D you must have been looking at my pics on Vortex! :eek:
I haven't seen your pics.. the irony is, 2-3 wheels is way worse than 4. Totally different loading!

Racing and high speed loads are different. They are typically shock loads. Rallying a car can be quite tough on a car and is good proof that the dubs can be tougher than the average unibody car.

But when you are crawling and "off-roading" you are slowly applying lots of loads and said loads have a very different effect.

It's very difficult to explain in text. Think of it like this when you high speed race, you often break things. When you are "crawling" you deform things. It's the application of load that is the main issue. Have you ever tried to break a piece of metal with your hands? You bend it over and over and over until it snaps? That's sort of the effect you will be doing to the chassis. And it's not going to like it. I don't know what parts are most likely to fail, but over time (short time *I* feel) the car will start to feel more and more rubbery and rattly. Panel gaps will appear, doors won't shut right. Things like this. Then again, I don't know how hard you'll wheel the thing. Maybe you're a pussy cat. If you have been doing stuff in a stocker and just want to make it easier/safer, my whole argument is probably a reasonably moot point. When I think off roading, i'm going places where a stock Jetta isn't going to go unless it's already attached to a Jeep, and isn't coming back. ;)

Again, not saying you can't do it, but it's going to be harsh on the car and you WILL shorten the chassis' life span.

For the electric drive.. no, technically you're right, you do WANT a capacitor. But they are more expensive and based on the current path of attack, you're not likely to buy a motor or have an amount of traction that will warrant them. An off the shelf lead acid will cost a fraction of a capacitor and provide you with more than enough power. If you were drag racing, a cap is a better choice. But you wouldn't need that. It's not warranted and a waste of resources. If you were to do it, spend more money on the motor. the true best bet (today) would be to build a bank of A123 cells or a bank of... uuhhh.. I am blanking on the name of the company. I want to call them Alpine, but I know that's not right. They are a variant of a Lithium cell. As are the A123s. Caps are best used if you need to drop a ton of power RIGHT NOW! When driving a motor, they are mostly a waste. A motor will use the power over a longer period of time. If you needed to put down 5000watts over the span of .001 second.. cap. But you'll be putting down 5000 watts over the span of.. umm.. more than 1 second so the cap is wasted resources. Adding a (some) caps to the system is good as it'll help the immediate power demands and help smooth out power delivery, but as a total bank, it's a waste.

As the the regen system. It's does depend slightly on your power source (Lead vs Lithium vs whatever). But seriously, it's really simple. Off the shelf power controllers will do 90% of the work for you. If the system calls for power and it's available, power is applied. If no power is called for and the motor is spinning, it's a generator and will charge the batteries. The DETAILS are more complicated.. but the reality is dirt simple.

Run a system like this into the AWD diff:
http://theeestory.com/files/UQM_PowerPhase125.pdf

And life is awesome. It's a plug and play system. I Want to say one of these mean machines was in the $1500-$2k range. Pricy, but for a plug and play setup, it's serious. Plus you'll be more than doubling your available HP and adding more useable torque than imagine.
 
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