EV (Electric Vehicle) Cooling

CSF is leading the way in performance cooling for Electric Vehicles & Emerging Technologies

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Electric Vehicles need cooling too

Many people don’t think of cooling systems when it comes to electric vehicles. However, there is a lot of heat produced by the battery pack and electric motors. While the systems are a little different than a traditional combustion engine, the principles of heat management are pretty much the same.

Most EVs are not designed with high performance driving in mind. Factory cooling systems on most EVs are suitable for daily and even a little spirited driving. However, it is very apparent how inadequate they are in a competitive setting. CSF has worked closely with a number of builders and race teams to help solve heat issues on high performance and race electric vehicles.

CSF is currently developing Plug-and-Play “Drop-in” Fit cooling solutions for popular EV models. Stay tuned and subscribe to our mailing list or social media channels for news about product development and releases.

Check out some of the projects and race cars CSF has worked with:

Take a look at the EV Conversion and EV Vehicle builders we supply cooling for:

Emerging Technologies

CSF works with some of the biggest names in the industry. Technologies like hydrogen fuel cells are becoming more main stream and CSF is there to cool it.

Emerging Technology products and projects:

Interested in EV Cooling Products for your custom project or company? Please use the inquiry form below.

Industry Garage – “The Legacy” EV 240Z

Tim Hicks, owner of Industry Garage, is well know for his wild and outlandish builds. He and his team continually turn out projects that shock the car community, and their latest project was no exception.

Starting life as a dilapidated 1977 Datsun 280Z that was nearly beyond saving. Industry Garage is no stranger to the S30 Chassis but wanted to do something extra special with this one. In just 6 months they custom made almost every panel for the car in carbon fiber, overhauled the entire car, and converted it to be all electric. The drive system is from a Tesla Model S which provides massive power to this ~2300lb coupe. The batteries are strategically placed through out the chassis to optimize balance while holding enough charge to complete grueling time attack races. Dual CSF “King Cooler” (CSF #7065/7065B) Universal Radiators were mounted in the rear for thermal management. One runs on a dedicated loop for the engine, and the other handles the batteries and charging system. Programing, Charging, and Control are handled by AEM Electronics.

A brief summary of the build can’t do it justice though so if you want to know the whole story and see attention to detail that went into this project check out the build series on Street Bandito’s YouTube Channel.

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Evasive Motorsport – Tesla Model 3

When Evasive Motorsport first started race testing their Model 3, they found that the factory cooling system just couldn’t handle much past short sprints. CSF worked closely with the team at Evasive to address these cooling issues.

The Tesla stock cooling system was V-mounted with a CSF R-1 Triple-Pass Competition Radiator (CSF #8023). Under the radiator is another heat exchanger for the electric motor oil. Overall, this setup nearly triples the available cooling.

The rear cooling was created by mounting another CSF R-1 Triple-Pass Competition Radiator (CSF #8023) and CSF Heat Exchanger in the trunk. This system is fed by custom duct work via custom scoops that replace the rear quarter windows.

At the 2022 Pikes Peak International Hill Climb, Evasive Motorsports’ 2018 Tesla Model 3 took 2nd in class (Exhibition) and 9th overall with a time of 11:06.205 driven by the world-renowned Dai Yoshihara. The team was also able to set a new EV record despite the poor conditions. Hopefully we’ll see this battery powered beast again at Pike Peak Hill Climb setting more records.

Read the full MotoIQ article about the Model 3’s development on their website.

Rywire – EV S2000

Not all EVs out there started life that way. EV swaps are becoming more and more common and you are sure to have seen at least one if you attended any car shows in the last few years. One of the most iconic swaps to date was performed by Ryan Basseri (owner of Rywire Motorsport Electronics) on his 2001 Honda S2000. Debuted at the 2021 SEMA Show, this EV Swap excited, thrilled, and upset countless enthusiasts.

Powered by two Chevy Volt power packs and large Telsa Performance drive unit, this EV S2000 boasts over 500HP. All the wiring and electronics were done in house by Rywire. While many don’t think about the complexities of performing an EV conversion, we can tell you a lot more went into this build than a custom harness. Heating and Cooling were also a big factor in getting this car running. They had to create a system that could heat up the batteries to optimal temperatures and then keep them there with a proper cooling setup. CSF was able to offer a solution on the cooling side and sent over two Dual-Pass Heat Exchangers (CSF #8030). Mounted behind the custom 3D Printed grille, these coolers manage all the heat from the Electric Motors.

If you’d like to learn more about the EV S2000 and everything that went into building it, check out Hoonigan’s YouTube special:

Rywire – AWD EV Civic EK Hatch

After having successfully tackling his first EV conversion with the S2000, Ryan set his sights on something even more wild. He was inspired by a ride in Von Gittin’s Ford Mach E 1400, an AWD 1,400hp EV built by Ford performance and RTR racing. Every performance aspect of that car blew him away and set his sights on creating something that could give a similar experience at a more reasonable price point. Ryan decided to base the new build on a Civic EK Hatchback but AWD and putting out way more power than would seem reasonable in a Civic.

The EK will be powered by two Tesla Model S drive units making over 600hp combined. Both with be powered by a total 85kw from 13 Tesla battery packs mounted in the floor and original fuel tank location. The current cooling setup is set to run the battery and motor fluids through the factory AC condenser and a CSF #2858X Ultimate Half Radiator. This project is still in progress and there are sure to be some changes made as it moves along. Be sure to stay tuned for more updates on this wild project.

Bisimoto – Porsche 935 k3v

One of the most unique EV Conversion ever done has to be Bisimoto’s 1984 Porsche 935. While there may be plenty of Porsche EV conversion examples out there, the 935 is not the average choice platform. Add to that all the custom work done to make this car, you can see why it is truly one of a kind.

“Building a project of this nature forced me to explore it, and since I desired to tackle the performance arena, why not use a chassis that would turn heads and raise awareness? The 935 K3V was born.”

Bisi Ezerioha

Inside this 935 K3 widebody you’ll find some of finest custom work. 403 volts from the single drive 475kW AC 3 phase induction motor equates to over 600hp on tap and able to spin to a ludicrous 18,200 RPM redline. The entire system is liquid cooled using a CSF #7053 high-performance radiator and two CSF #8119 dual-pass oil coolers. The radiator handles cooling for the Motor, Stator, and Inverter while the two oil coolers manage the battery.

Read more about the Porsche 935 K3V on MotorTrend and The SpeedHunters.

Bisimoto – Porsche 935 Moby X

After the massive success of the Porsche 935 K3V, Bisimoto decided to really take things to the next level. An EV converted 935 is already rare, but what if you were to build an EV version of the Legendary Porsche 935 Moby Dick? In January of 2021, Bisimoto shocked the automotive world when announcing his newest project car, the Moby X. Don’t have a heat attack quite yet, this isn’t actually an original Le Mans prepped 935 Moby Dick. However, it is a near perfect replica with some modern tweaks by designer Khyzyl Saleem.

While all the finer details about this build have not been release, as the official cooling partner on this build we can at least comment on that. The Moby X is running two CSF #7053 high-performance radiators (originally designed for 996/997 GT2 & GT3 Porsches). One radiator is dedicated to cooling the electric motor while the other is setup for battery thermal management. Needless to say, this is one of the wilder EV builds out there.

Electric GT – EV Conversion Systems

Electric GT is one of the industry leaders in Electric Vehicle Powertrains, Battery Systems, Components, and complete conversion packages (vehicle systems). You have probably seen some of their work somewhere online. They have been featured in The New York Times, Road & Track, Top Gear, and WIRED.

While EV conversions might not be the most popular thing yet, there is no denying they can be tasteful, reliable, and a load of fun. Electric GT uses the CSF #8132 as their heat exchanger for their EV systems. The quadruple pass design and compact size makes it the ideal cooler for their systems. They sell this cooling system independently for those building their own conversions.

While some may still be skeptical about EV Conversions, there is no denying that eGT does phenomenal work. Here are some examples of the complete systems they offer:

Egt913 – Porsche 911/912/964

Fiat 124 Spider EV System

FJ40 Series Land Cruiser EV System

APP EV Systems – BEV powertrain conversion kits

APP EV Systems designs, builds, and will sell, turn-key Battery Electric Vehicle (BEV) powertrain conversion kits to owners of internal combustion powered classic vehicles. These kits have been engineered and validated to OEM specifications. Now, electrifying your classic car is easier than an engine rebuild.

The APP systems are sold 100% complete. All components are pre-populated on the application specific carbon fiber mounting sub frames. The systems use battery packs made in house of High Temp BMI fire retardant glass fiber with impact resistant Kevlar out casings for maximum protection. For cooling, APP uses the CSF #8132 because of its compact design and high efficiency.

The APP EV platform will be available to owners of the following beloved classics. This kit will be sold first in North America, followed by TUV certification and export to European markets.

Powertrain Control Solutions

Coming soon…

Other EV related products and projects

Toyota Racing Development (TRD) – Hydrogen Fuel Cell Generator

TRD’s Emerging Technology team debuted our Hydrogen Fuel Cell Generator at the Pickathon Music Festival near Portland, Oregon in August 2023. The zero-emission technology and noise free power capabilities were truly awe inspiring. TRD’s Fuel Cell Generator headed to the Pebble Beach Concours D’Elegance event to support Lexus with an EV charging station for their electric cars.

With any type of power plant, there is always heat as a byproduct and Toyota’s new generator is no exception. TRD needed a custom heat exchanger/radiator for these generators and turned to the Cooling Experts at CSF. CSF’s knowledge and experience was invaluable to the team at Toyota in developing and manufacturing the ideal cooling solution.

With Lexus at Concours D’Elegance

Lexus invited TRD Emerging Technology team to Showcase the possibilities of H2 technology combined with Level 2 EV charging at the prestigious Concours D’Elegance event in Pebble Beach, Monterrey CA. TRD also offered a sneak peek of the all-new Fuel Cell Generator truck.

Tundra Mounted Generator

Toyota/TRD just completed their new truck bed mounted Hydrogen Fuel Cell Generator. Offering more mobility to the system by placing it in the back of a Tundra is Toyota’s latest step in furthering this technology.

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