Vendor Newsmaker Q&A David Benardo

March 12, 2018
David Benardo’s Zelectric Motors shop in San Diego specializes in converting vintage petroleum-powered Volkswagens and Porsches into electric vehicles.

David Benardo’s Zelectric Motors shop in San Diego specializes in converting vintage petroleum-powered Volkswagens and Porsches into electric vehicles.

The emphasis is on retaining and exquisitely refinishing the original outward appearance – replacing the internal combustion engine with an EV powertrain and discretely updating and modernizing the various components throughout.

Additional engineering and conversion expertise is frequently subcontracted out to parts and services provider EV West of San Marcos, Calif.

Established in 2012, Zelectric “is not and never will be a factory assembly line operation,” Benardo explains. “Each vehicle is meticulously rebuilt by hand into retro-futuristic experiential art on wheels. By the nature of the business itself, production will always be limited to bespoke creations, each somewhat unique.”

His wife, Bonnie Rodgers, manages the office and marketing aspects while assisting in locating stock classic car candidates suitable for undergoing the EV conversion process.

Benardo, who describes himself as the shop’s “CEO, Director of R&D and RetroFuturist,” recently provided some insights into Zelectric’s operational details:

Q: Do you sell complete vehicles?

A: Yes. We offer turnkey classics that are reborn electric, meticulously hand-rebuilt to order. Drivetrain conversion from fossil fuel is the hallmark of the Zelectric rebuild. But in addition, select upgrades and modifications ensure a dramatically improved driving experience. We use only proven components from world-class suppliers.

Q: Do you have a kit so I can do it myself?

A: No. It’s complicated. Individual components used in the basic electric conversion cost around $20,000, and that does not include Zelectric’s additional mechanical and proprietary modifications to support the conversion. When purchased alone, conversion components do not come with instructions for assembly or installation.

Q: What does a turnkey Zelectric cost?

A: Typical ZelectricBug sedans start at $73,500. But every car is a midcentury classic and is priced according to its unique characteristics. Less common sunroof (ragtop) models generally run $10,000-$15,000 higher and the highly desirable convertibles can add an additional $20,000 or more. We specialize in finding exceptional candidates, or may have one currently available.

Base price varies according to the model and year of the vehicle you envision. For a ballpark cost estimate on Microbuses, Karmann Ghias, and VW Things add $55,000-$75,000 (Zelectric retrofit and conversion) to the current (excellent condition) market value of the “core” vehicle that you have in mind. Extra options are available.

Q: Will you zelectrify my air-cooled car or microbus?

A: Yes. But, other than its engine, your vehicle must be in excellent condition. Including our proprietary upgrades, modifications and conversion, the base price for retrofitting your Beetle, Karmann Ghia, or VW Thing is $54,500. A Microbus Zelectric rebuild starts at $61,500. Shipping will be your responsibility; all work takes place at our San Diego shop.

Q: Which years? Which models?

A: Volkswagens and Porsches exclusively, mostly pre-1979. Beetles, Buses, Ghias, and yes, even ZelectricThings. Porsche 911, 356 and 914s. Tech evolved, design preserved. Turnkey air-cooled classics – rebuilt, reborn electric and made road-ready for the 21st century.

Q: Why the Beetle?

A: The iconic Bug’s universal popularity continues half a century after it was first built, along with a robust worldwide industry supporting VW owners. Thousands of specialized mechanics, owners’ clubs and parts manufacturers can be found almost everywhere.

Q: What makes the early Bug the perfect candidate for a high-performance electric drive?

A: The simplicity of the car’s design and its light weight are exceptional. And unbounded personality, character – where today’s modern EVs come up short.

Q: What specifically makes for a good Zelectric candidate?

A: First and foremost, ask yourself: Is it investment-worthy? Other than the engine, the car should be in good working condition, with a manual transmission, and a curb weight under 2,000 pounds. Most smaller 1960s cars (along with a few ‘50s and ‘70s) meet these requirements.

Q: What’s the range?

A: The basic Zelectric retrofit for Beetle and Karmann Ghia provides a range of 100 miles on a full charge. Due to a lack of aerodynamic design, the Microbus and Thing will be less, but in some cases range can be extended with the use of additional batteries, depending on the vehicle model. In order to preserve the investment quality of the stock vehicle, we avoid cutting and welding.

Q: What about charging? Where can you charge-up, and how long does that take?

A: Zelectrics come with a Level 1 charging cord. Both Level 1 and 2 chargers work in a typical garage or carport, no special installation required. If you drive 50 miles, on a level 1 charge (110 volts) it will take about 6-8 hours. A Level 2 charge (220 volts) works twice as fast. Basically, you’ll plug your car in overnight, like your cell phone.

Q: Top speed?

A: The ZelectricBug is capable of 100-plus mph. Horsepower is more than doubled. Instant, selectable torque means fast feels faster.

Q: What about a warranty?

A: All of the new electrical components have individual warranties from their respective manufacturers. The rest of the car, like every classic, is sold on an “as is” basis, but subject to our verified 100-plus checkpoint first, to ensure that all systems are in top-flight working order prior to delivery.

Q: How much will fuel cost to drive 100 miles?

A: On solar power, of course the cost equals zero. Otherwise, it will depend on electricity rates where you live. Here in San Diego, rates are the most expensive in California. Even here, driving 100 miles costs less than $3.00 – that’s like getting 116 miles on a gallon of gasoline.

Q: What about exporting? Is that a problem?

A: Regulations concerning the import and registration of a vintage electric-converted vehicle vary by country. We can’t take responsibility for compliance, but will adapt the build to suit your requirements within the scope of our capabilities. We will be happy to work with your customs import specialist and coordinate delivery with the transportation services you select.

Q: What’s the payment schedule?

A: $5,000 holding deposit reserves your place in the Zelectric production schedule; 50 percent of the total project is due when scheduled project work begins. This provides funding for acquisition of the core vehicle and allows us to place the order for specific parts required to begin the build.

Q: If I order a car from you, how long until delivery?

A: The timetable varies. Generally no more than 6 months after work on your project build begins. Often less.

Q: After my production order and initial payment, how will I track progress on the car?

A: Once your vehicle goes into production, you will be updated every 30 days. You will receive digital photos of work accomplished to date, along with billing for labor and material costs exceeding the initial deposit. Your vehicle will be built strictly according to your original purchase agreement’s build sheet.

Q: What are your credentials?

A: Zelectric Motors offers the finest re-configuration and electric propulsion of vintage VWs available today. Our re-engineering design is the product of the same specialized team that built the record-holding fastest street-legal electric at the Pike’s Peak Hill Climb in 2012. Zelectrics have been featured at a number of Concours d’Elegance events, won various awards, and have been reviewed and celebrated internationally by worldwide media – from The Wall Street Journal and CNN to the Robb Report.

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