Hyundai EV Rally Car

NEW ZEALAND’S NUMBER 1 RALLY TEAM

The future is coming and the future is here at Paddon Rallysport Group. After the initial idea come together in 2017, a group of some of the brightest young engineers and technicians was formed in late 2018 to begin the project to construct one of the first EV Rally Cars in the world.

While EV technology already exists in several forms of motorsport, rallying presents the biggest challenge to make this ever evolving technology work in the most demanding of motorsport environments. It’s about combining performance, range and reliability into one package. At PRG the design concept is to create an EV platform that is not only fast and spectacular, but one that can compete in a traditional rally format up against normal IC competition.

Working with our technical partner STARD, PRG will then develop a lot of the systems and some unique technology that sets our EV project apart. New Zealand also provides the best test facilities on our back door step – with an international race circuit at our facility and gravel roads stretching around the mountains surrounding our Central Otago base.

Our time frame for our project is:

  • Prototype 1 built and running August 2020
  • Public testing and development August-December 2020
  • Competing in New Zealand rally’s and championships 2021
EV-clear
Hyundai EV Rally Car Specs
MotorsBrusa BLDC Motor
Potential configuration 2, 3 or 4 motors
Each motor peak power 220kw
Up to 1,100Nm torque
Customized cooling system
Customized front/rear torque vectoring
TyresPirelli range
15' Gravel, 18' Tarmac
EVO Corse lightweight Alloy wheels
CockpitRacetech seats, belts, steering wheel
MoTec M1 management system
MoTec PDU and driver displays
MoTec keypad
Chassis / SuspensionFront / Rear EXT MacPherson struts with 5 way adjustable dampers (new technology)
Steering electric power-assisted rack and pinion
Braking system ventilated Brembo disc brakes (355mm on tarmac; 300mm on gravel), Air-cooled 4-piston calipers
Handbrake Hydraulic control
TransmissionTwin transmission
Paddle shift gear selection - MoTec controlled
Driver controlled torque settings
Chassis / BodyworkSteel bodyshell with welded multi-point chromoly roll cage. Extensive chassis strengthening
Bodywork Steel and composite fiber panels
UC designed Aero package for a combination of down-force and reduced drag
WeightExpected weight approx 1500kg (with battery)
Hyundai
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January 2019

New team base acquired and setup at the spectacular Highlands Motorsport Park with direct access to international race circuit. Perfect testing and development facilities.

Soon after 6 young engineers and technicians join the team including Matt, Rory, Ben, Jack, Mike and Vanessa. The basis was now in place to push forward on the EV concept that had spent the last 12 months on planning.

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August 2019

At a worldwide media event streamed around the world, we share our vision and project to the motorsport community.

While the design phase was well under way at this point, the physical build had yet to start. Making sure all the boxes were ticked, we analysed the perfect chassis and geometry using data from existing cars and simulation data utilizing the whole new weight distribution of the car given the extra weight of the batteries.

At this time we also took delivery of a brand new Hyundai Kona to be used as a donor car.

October 2019

After 8 months of design and simulation, the chassis and geometry design was complete. This meant that the chassis build could start with confidence.

Design continues working alongside STARD on the systems and drive-line of the car and the all important battery pack.

The first prototype battery will be a smaller pack to allow us to simulate power use once the car is up and running to incorporate the full size rally battery during 2020.

November 2019

Our technicians Mike and Ben got to work on preparing the body shell which will include over 500 hours of work over the coming months.

After stripping the brand new car to a bare shell, work then began on lightening the shell as much as possible to compensate for the extra weight of the batteries.

Then, after making the Jig, strut towers and suspension points are inserted before work begins on a whole new floor and battery mounting to allow for quick battery changes.

February 2020

Chassis construction ramps up with finalised roll-cage and floor design.

The chromoly cage that is tig welded has also been designed to strengthen the subframe pick up points and to support the floor where the battery will be mounted.

Engineers also are close to finalizing designs of auxiliary components including cooling system and power steer system.

Suspension design has been confirmed with our partner EXT Shox and construction under way.

Our components from technical partner, STARD also arrived including transmissions, motors and inverters.

May 2020

Body shell now complete with roll cage, strut towers and all suspension points. This meant dummy fitting of subframes and major components can now start.

Over past months sub-assembly and construction has also been busy getting each component ready to be fitted to the chassis when ready. This included the delivery of our aero kit that was developed in conjunction with the University of Canterbury.

Systems and components now begin bench testing before dummy fitting the car together.

Check back soon to follow developments

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