Selection of VASS specialist engineering projects

Selected work

Engineering Projects

Real project experience across EV conversions, diagnostics, custom electronics, vehicle systems and specialist development support.
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Practical experience

Vehicles and systems VASS has helped move forward

Each case study gives prospective clients the useful facts: the starting problem, VASS scope, systems involved, engineering challenge and practical outcome.

Left hand drive Land Rover Defender Puma EV conversion with 100 kWh Tesla battery pack and active cooling system

Full EV conversion / bespoke systems integration

UAE Puma Defender EV with 100 kWh Tesla Battery and Active Cooling

A highly integrated Puma Defender EV conversion built around a 100 kWh Tesla Model S/X battery pack, Tesla Model 3 motor kit, OEM-style gear selector, reverse-engineered Defender gauges and active cabin and battery cooling for hot-climate use.

Vehicle / platform
Left-hand-drive Land Rover Defender Puma for UAE use
VASS scope
Tesla Model S/X 100 kWh battery pack integration · Tesla Model 3 motor kit installation and EV drivetrain commissioning
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1970 classic Mini EV conversion with Tesla Small Drive Unit and 35 kWh battery pack

Classic car EV conversion / full restoration support

Tesla Small Drive Unit Classic Mini EV Conversion

A 1970 Mini EV build using a Tesla Small Drive Unit, 35 kWh battery pack and 7 kW AC charging. The project required major packaging work, drivetrain upgrades, custom shafts, braking improvements, limited-slip differential installation and careful torque mapping to make the car usable on the road.

Vehicle / platform
1970 classic Mini with front-wheel-drive Tesla Small Drive Unit
VASS scope
Removed the previous EV concept and moved to a Tesla Small Drive Unit package · Serviced and prepared the Tesla drive unit
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Skyfly electric aircraft prototype during electrical and control system integration testing

Electric aircraft electrical integration / control systems support

Skyfly Electric Aircraft Electrical and Control Integration Support

Electrical and control integration support for Skyfly’s electric aircraft development, helping battery, powertrain and main control systems communicate and operate together through remote testing, tethered hovering and early low-level flight testing.

Vehicle / platform
Skyfly electric aircraft prototype and full-scale test aircraft systems
VASS scope
Investigated how full-scale aircraft components communicated and operated · Supported integration of battery and powertrain systems
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Electric Land Rover Defender 90 soft top with 83 kWh Jaguar I-Pace battery pack and Tesla Model 3 motor

EV conversion / show car / development mule

Defender 90 EV Show Car with 83 kWh Jaguar I-Pace Battery

A Defender 90 EV show car and development mule using an 83 kWh Jaguar I-Pace module battery pack, Tesla Model 3 motor with custom gearset, 75 kW CCS charging, new chassis and front/rear battery packaging for weight balance and service access.

Vehicle / platform
Land Rover Defender 90 soft-top EV
VASS scope
New chassis Defender 90 EV build support · Soft-top conversion support
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TVR Wedge electric vehicle conversion undergoing electrical diagnostics and EV rectification work by VASS Technology and ChargeheadsUK

EV rectification / specialist project support

TVR Wedge EV Rectification with ChargeheadsUK

A specialist EV rectification and refinement project carried out on a TVR Wedge electric conversion in collaboration with ChargeheadsUK. The work focuses on bringing the car safely and reliably back to the road through electrical diagnostics, system checks and engineering improvements.

Vehicle / platform
TVR Wedge EV conversion
VASS scope
Electrical system inspection · EV system diagnostics
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Twisted Land Rover Defender EV conversion undergoing charging diagnostics and onboard charger repair support by VASS Technology

EV diagnostics / charging system repair

Twisted Defender EV Charging Diagnostics

Specialist diagnostics and repair support for an EV-converted Land Rover Defender by Twisted. The vehicle arrived with a charging fault, and VASS traced the issue to the onboard charger, coordinated the repair process, reinstalled the system and returned the vehicle to full working order.

Vehicle / platform
Land Rover Defender EV conversion by Twisted
VASS scope
Charging system diagnostics · Onboard charger fault investigation
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First VASS electric Defender prototype with Tesla Model 3 motor and compact 35 kWh battery pack

EV conversion prototype / final commissioning

First VASS EV Defender Prototype Final Testing and Commissioning

The first VASS EV Defender prototype used a Tesla Model 3 motor in place of the transfer case, a compact 35 kWh battery pack, 7 kW AC charging and 30 kW CCS. The vehicle was completed in early 2022 and remains in use as a practical coastal run-around.

Vehicle / platform
Classic Land Rover Defender EV prototype
VASS scope
Final EV system testing and commissioning · Drivability testing
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Porsche 911 EV conversion undergoing high-voltage isolation fault diagnosis and battery inspection

EV rectification / high-voltage diagnostics

Porsche 911 EV Rectification and High-Voltage Isolation Fault Diagnosis

High-voltage diagnostic and rectification work on a Porsche 911 EV conversion. The vehicle was made safe, diagnostics showed isolation faults, the battery system was safely reduced and removed, and a serious rear battery pack issue was identified.

Vehicle / platform
Porsche 911 EV conversion
VASS scope
Initial EV system safety assessment · Diagnostic scan and fault review
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Classic Mini EV conversion during 12V wiring and CAN bus commissioning work

EV rectification / electrical commissioning

Pre-Electrified Classic Mini 12V Rewire and CAN Commissioning

A partially electrified classic Mini arrived with the main EV hardware already installed but only a basic 12V system. The work focused on rewiring, CAN bus debugging, message deciphering and commissioning the vehicle until charging, motor operation and EV boot-up worked correctly.

Vehicle / platform
Classic Mini EV conversion
VASS scope
12V system rewiring · Basic electrical system correction
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Land Rover Defender restomod with LT1 V8 and 10L80 gearbox wiring integration

Restomod wiring / modern powertrain integration

LT1 V8 Defender Restomod Wiring and 10L80 Powertrain Integration

A modern V8 Defender restomod project using an LT1 engine and 10L80 automatic gearbox. VASS supported the wiring for the vehicle and powertrain, including electric windows, central locking, upgraded audio, reversing camera and production-focused scanning work.

Vehicle / platform
Land Rover Defender with LT1 V8 and 10L80 automatic gearbox
VASS scope
Custom vehicle wiring harness design/support · LT1 V8 powertrain wiring integration
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Land Rover Defender TD5 automatic gearbox conversion with custom centre console development

Transmission conversion / electrical integration / interior development

TD5 Defender Automatic Gearbox Conversion and Centre Console Development

Electrical integration support for fitting an automatic gearbox into a TD5 Defender, including professional harness integration, transmission controller data, gearbox software tuning and development support for a full-length custom centre console with integrated subwoofer.

Vehicle / platform
Land Rover Defender TD5 automatic conversion
VASS scope
Professional transmission harness integration · Original wiring harness interface work
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Classic Range Rover 6x6 ultra range EV development study based on a former fire engine platform

EV development study / extreme range concept

Range Rover 6x6 Ultra-Range EV Development Study

An ambitious development study for a classic Range Rover 6x6 EV intended to attempt an extreme UK range record. The concept explored five VW battery packs in parallel, lightweighting work and control strategies for safely managing multiple large EV packs.

Vehicle / platform
Classic Range Rover 6x6 former fire engine
VASS scope
Concept development for an extreme-range EV · Classic Range Rover 6x6 platform selection
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