Patina-Cool 1966 VW EV Conversion

Jonny 5’s Long-Haul VW Build

A Project Years in the Making

The “Jytr Bug,” as shown on its custom license plate, is a 1966 Volkswagen Beetle that’s been given a new lease on life as an EV. Now powered by an AC-50 motor, it belongs to John Garcia, better known as “Jonny 5”, who picked up the project after it had already spent years bouncing around within his family.

I get to enjoy the car at a time when vehicles feel like robots. This car has soul.

Don’t be fooled by the patina, this bug has gone through an extensive refresh.

The car first came into the family around 2010, bought from a friend of Jonny’s mom. In its early years the VW was a simple daily driver, rumbling its way to Channel 8 News each morning. But by the time Jonny got his hands on it, the Bug had seen better days.

The Bug as it looked when Jonny’s family first picked it up.

“When the car was originally brought into my family, my father had dreams of restoring it into a clean, gas-powered Bug,” Garcia explains. “But when we got it, the transmission was broken. When I pulled the engine, the input shaft came out with it, which obviously wasn’t right. I ended up swapping in another transmission I had and putting it back together.”

The Bug was driven in rough condition for some time until Jonny’s father flat towed it to Texas, where he was working at the time, for restoration. While there, he installed lowering spindles, front disc brakes, and a new Rancho race transmission.

Going Electric (Eventually)

The EV swap wasn’t always the plan. When Jonny’s father returned from Texas, the Bug came back to California; without an engine. At the time, the goal was to install a gas-powered Subaru engine.

Simple, tidy wiring under the hood, with a small lawn and garden 12V battery.

“It was going to be gas-powered until one day at work I asked my boss, Michael, what it would take to set up an AC-50 in my Bug. I was working at EV West then, so it was hard not to think about EV swaps all day.”

The bug sits outside Peppertree Frosty, Jonny’s old high school hangout.

With his father busy on the road, Jonny officially took over the project around 2019. That’s when the Bug’s true transformation began.

“I stripped it down to the last bolt. The pans were toast, so those got replaced. The brake lines, the brakes, everything had to go. The car’s age really took its toll,” Garcia explains.

The charging port is cleverly hidden behind a vintage airplane-style fuel door.

Despite working on several custom EV projects like the Electraliner land-speed racer and “Luxi,” the Tesla-powered 1972 Toyota Hilux previously featured in EV Builders Guide, Jonny continued chipping away at the Bug when time allowed.

Original VW badge up front—one of the few parts that stayed.

“This was always the back-burner project. I could only spend about three days a month on it. It took a massive push. (And now) It feels like the only original parts left are the logos.”

Bringing a ’60s Bug into the 21st Century

Now powering the Bug is an HPEVS AC-50 electric motor controlled by a Curtis 96V controller. It’s bolted to a Rancho racing transmission with freeway flyer gears and a 4-pin differential, using an adapter from EV West. Four Tesla Model S battery modules provide around 20.8kWh of energy, offering a peak voltage near 100V. Thunderstruck’s BMSC and EVCC are put to work managing the battery and charging functions. The HV battery charges through a Thunderstruck charger and a Elcon DC-DC converter keeps the 12V battery topped off.

A look inside the cabin after the refresh.

Much of the original work Jonny’s father did, like the front disc brake conversion, has been refreshed or replaced entirely. Jonny also took the car down to bare bones with a full pan-off restoration, installing new pans, brake lines, and a rebuilt braking system. The body was sanded and painted, then finished with a “natural” rustic patina.

Jonny backs out for a cruise to Peppertree Frosty.

The suspension was updated with a 3-inch narrowed front beam and lowering spindles, paired with adjustable spring plates in the rear for a more balanced stance. Up front, the car rides on restored stock VW wheels with VEENTO G-2 165/80R15 tires. In back, wider Bezos Speed and Machine wheels wear Hankook Kinergy ST 215/65R15s for extra grip and a more planted look. Additional upgrades include a new 12V wiring harness, a small lawn and garden battery, a Yamaha YZF450 radiator, and a Tesla water pump. The charging port, hidden behind a studded airplane-style fuel door on the passenger rear quarter, adds a clever retro touch.

Now it feels like the only original parts left are the logos.

Tesla Model 3 seats fit surprisingly well and keep things comfortable.

Wider rear wheels and tires provide a better grip and a more balanced stance.

Inside, fresh carpet lays the groundwork for a more modern surprise: Tesla Model 3 seats, front and rear! They still function fully, heaters and all. Rear legroom is a bit tighter now, but the comfort upgrade is worth it, offering a modern feel without clashing with the vintage vibe.

What’s Next?

“I always dreamed of taking the Bug to the beach or Peppertree, my favorite hometown spot. I’ve been going there since I was a kid and in high school, it was our hangout spot. I’ve been to a lot of car shows there, and it’s my favorite place to grab a burger and ice cream,” Garcia shares.

The AC-50 motor sits mounted out back, painted in Jonny’s signature red.

Now that the dream is reality, Jonny feels like he’s finally closed the chapter on this build.

“I get to enjoy the car at a time when vehicles feel like robots. This car has soul.”

Still, with limited space and time for all the builds he’s working on, Jonny 5 plans to eventually sell this beautifully restored Bug to make room for new projects. And there are plenty in the pipeline.

A peek through the back window reveals some of the key EV components.

You can follow Jonny 5’s EV adventures on Instagram:
@j5_jonny5 & @j5dynamics. His next builds include a retro ’87 Taylor-Dunn R680 utility cart dubbed “Glenn” , a small but mighty project that already sports his signature patina style.

SPECS

1966 Volkswagen Beetle

Vehicle Name: JYTR BUG
Owner/Builder: John Garcia aka “Jonny 5”
Location: Vista, CA

POWERTRAIN

Motor: HPEVS AC-50
Controller: Curtis 96V
Transmission: Rancho racing transaxle
4-pin differential
Freeway flyer gears
EV West adapter plate
Battery Pack: 4x Tesla Model S modules
20.8kWh total capacity
~100V max voltage
Battery Management: Thunderstruck BMSC
Charger: Thunderstruck
DC-DC Converter: Elcon
Cooling System: Yamaha YZF450 radiator and Tesla water pump
12V Battery: Super Start Lawn & Garden
12V Wiring: New harness installed
Charge Port: Custom J1772, hidden behind retro airplane-style fuel door on passenger rear quarter

CHASSIS & SUSPENSION

Front Beam: 3” narrowed custom beam
Spindles: Lowering spindles
Rear Suspension: Adjustable spring plates
Braking: Refreshed front disc brakes, new brake lines, and fully rebuilt system

WHEELS & TIRES

Front Wheels: Restored stock VW
Front Tires: VEENTO G-2 165/80R15
Rear Wheels: Bezos Speed and Machine
Rear Tires: Hankook Kinergy ST 215/65R15

INTERIOR

Seating: Tesla Model 3 seats (front and rear) with functioning seat heaters and adjusters
Other Updates: New carpeting, clean wiring, and subtle EV integration throughout

BODY & EXTERIOR

Restoration: Full pan-off restoration including new pans, refreshed braking system, and bodywork
Finish: Sanded and sealed natural patina
Custom Touches: Hidden J1772 charge port, original badging, “Jytr Bug” custom license plate

Photos by Dan Coronado