South African electric Beetle running on Tesla batteries

South African solar rental provider Stage Zero has a one-of-a-kind vehicle at its factory in Cape Town — a classic 1972 Volkswagen Beetle converted to run off the same battery modules as a Tesla Model S.

The electric vehicle (EV) conversion was done as a research and design project to better understand EV technology and its application in the South African context.

“The goal was to build our own EV to gain hands-on experience with how these systems work, especially in the context of South Africa’s energy infrastructure,” Stage Zero told MyBroadband.

“We wanted to explore how DC and AC charging works in real-world conditions, what’s feasible in terms of conversion, and what challenges exist for consumers in South Africa.”

Stage Zero argues that the transition to EVs is inevitable although South Africa is lagging behind major markets like Europe by about six years.

“The shift won’t just be about installing more charging stations but will require strategic energy planning to accommodate an electrified transport sector,” the company said.

Stage Zero’s EV R&D helps inform and strengthen its residential solar rental proposition, because many people will be charging their EVs from home.

“Just like petrol stations used to be the go-to for fuel, most EV charging will take place at home—provided people have the right charging solutions,” the company explained.

“The ability to charge EVs with solar energy will be a game-changer, reducing dependency on the national grid while keeping costs down for consumers.”

“Because we built the vehicle ourselves, we had the freedom to push its limits, test components, and refine our knowledge.”

Stage Zero said the converted Beetle — nicknamed the Zero Bug — has become a fantastic marketing tool, especially among petrolheads.

At the time the idea for the electric Beetle conversion began in 2022, EVs were still prohibitively expensive.

Stage Zero decided to build their own for much cheaper by sourcing and shipping the necessary parts at the end of 2022 and early 2023, officially kicking off the project in mid-2023.

Stage Zero said the conversion itself took longer than usual because it was conducted alongside other business operations.

“Under normal circumstances, a full-time EV conversion (excluding bodywork) could be completed within a few weeks.”

The Beetle was fitted with a NetGain HyPer9 AC motor, configured to produce 88kW of power.

Its top speed is limited to 160km/h for safety reasons, while acceleration is comparable to a modern small petrol-powered hatchback.

“While the motor itself is capable of higher output, we’ve chosen to limit performance to ensure drivability and long-term reliability,” Stage Zero said.

“This is especially important given the increased weight of the battery pack.”

To supply its energy, the Beetle has a 26.5kWh battery pack consisting of five battery modules also used in the Tesla Model S.

The pack supportis a real-world range of approximately 400km on a full charge.

“We opted not to add more batteries, as this setup balances performance, weight, and practicality,” Stage Zero said.

To accommodate the battery’s additional weight, Stage Zero had to strip down the Beetle to its chassis and upgrade several components, including adding racing suspension and upgrading to a better drivetrain and brakes.

“The result is a fully functional daily driver with a classic look and modern electric performance,” Stage Zero said.

EV conversions gaining traction in South Africa

Stage Zero is not the first and will likely not be the last to convert a classic car to run on electricity rather than petrol.

Battery manufacturer Freedom Won was established based on the battery technology lessons that one of its founders, Antony English, gained from converting his Jeep Grand Cherokee to electric in 2010.

It is likely to be South Africa’s oldest working electric car, considering mass-produced EVs only went on sale locally from 2013 and the older Optimal Energy Joule prototypes are not currently running.

In its early days, Freedom Won converted several more vehicles, including a Citroën C1 and Fiat 500.

Former F1 engineer Anthony Abbott has also established a company in Johannesburg dedicated to converting classic cars to EVs.

It has converted several classic Land Rovers to run on electric power and has developed a kit for the VW Beetle.

Stage Zero said there were also converted AC Cobras and VW buses in Cape Town.

“EV conversions are gaining momentum locally, and while they’re still niche, interest is growing rapidly.”