Reviving auto shop class for the electric vehicle era, one vintage VW at a time

Reviving auto shop class for the electric vehicle era, one vintage VW at a time

High school teacher revitalizes his class by launching EV conversion course

Editor’s note: This article was submitted by Volkswagen of America

When Ron Grosinger began teaching shop class in 2005 at Memorial High School in West New York, New Jersey, the program was struggling to survive. In a school facing many challenges, the elective course had dwindled from six teachers to two and rarely offered any hands-on learning, Grosinger said.

As in many schools across the country, the shop program was on the path to being eliminated. Between the extra cost of running capital-intensive classes and a growing focus on college preparation, enrollment in vocational classes had dwindled – even with a growing economic need for future mechanics.

To keep the class afloat, Grosinger knew he’d have to get creative to stay relevant. 

This 1990 Volkswagen Cabriolet was the converted to electric power by high school students

“If you’re teaching students about gasoline cars, that’s basically the equivalent of 8-track players,” Grosinger said.

So, in 2008, he approached the school’s administrators with an innovative idea: he would teach his 27 students, step-by-step, how to convert a gasoline-driven car to electric power.

“With the electric car, I wanted to prove two things,” said Grosinger. “First, [I wanted to prove] that we could convert it. Everyone was telling me at the time that it was impossible when really, we just didn’t have the option yet [on a large scale].

“Second, and most important, I wanted to prove that kids are super capable. You just have to give them a chance.”

Grosinger had taken an intensive, two-week EV conversion course in San Diego and believed an updated auto shop program would help to teach students applied science and engineering principles through automotive applications. With backing from the school, he was able to purchase his first conversion vehicle: a 1990 Volkswagen Cabriolet.

“Volkswagen vehicles are known for their German engineering and affordability,” he said. “They’re built with no-nonsense and the parts are readily available. They’re also relatively lightweight, which is great for electric conversion and helps keep the battery costs down for the class. … All the money you put into them is worth it.”

Isamara Lozano and Ron Grosinger seem to enjoy getting their photos taken

Over time, the students learned how to produce the various mechanical parts in cardboard, and then in wood, then then in steel. They welded parts, tackled wiring and learned to solve problems as they arose.

“We completely gutted the car and put it all back together,” Grosinger said.

Within a year, he noticed the student makeup of the class had expanded to advanced math, science, physics and engineering students. Also, there were many more female students.

 “The girls in my classes are amazing engineers,” he said. “Through hands-on learning, I hope they are encouraged to maintain and broaden their interest in STEM careers.” 

His goal is to get the male to female ratio to 50-50.

Every year since his first year of teaching, Grosinger has upped the ante and challenged his class to take on new projects. In the decade since the program was revamped, enrollment has increased dramatically. The department has expanded to four teachers and the school added an after-school automotive program.

Ron Grosinger and the VW won an Editor’s Choice blue ribbon at a Maker Faire

“Teachers should encourage students to explore new and more efficient ways to move a person from point A to point B, whether that system is a train with solar panels on it, a car with an electric motor in it or retrofitting an existing technology with a different energy source,” said Grosinger. “And don’t come up with the solutions for the students.”

The various automotive build projects have also led to grant money that has helped pay for new and improved equipment. Most importantly, several of Grosinger’s students have gone on to work in the automotive field.

Grosinger attributes the popularity and growth of these courses to the promotion of STEM subjects and the infusion of high-tech equipment, like 3D printers, in the programs.

“It’s all about giving students options,” he says.

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