150 Years of NSU: Prinz EP4 e-tron

On July 8, 2023, the apprentices from the automotive mechatronics, body and vehicle construction mechanics, and painting training programs unveiled the "EP4". The "E" in the name stands for the electric motor and "P4" for the NSU Prinz 4, a model that NSU Motorenwerke built in Neckarsulm from 1961 to 1973. Dean Scheuffler, an apprentice automotive mechatronics technician at Audi in Neckarsulm, explains:

"We wanted to build a car that is not only fast and cool looking but also fits the 150th-anniversary celebration at the site."

The Prince was awakened from its Sleeping Beauty slumber

The base was an NSU Prinz 4 from the year 1971, which had been decommissioned for many years until January 2023. The apprentices awakened this "Prince" from its Sleeping Beauty slumber and revived it with a new high-voltage heart.

But from the project start in January until the ceremonial presentation on Family Day, it was a long road. In numerous team meetings, apprentices, trainers, and project management exchanged information on the project's status, current challenges, and the next steps. The first task was to create a solid foundation for the later modifications. Mizgar Doman Hassan, an apprentice body and vehicle construction mechanic, recalls:

"When we received the car, the body had multiple rust spots. These were the first to be addressed."

The drive: Now quiet, electrifying, and emission-free with 240 instead of 30 horsepower

While the future body and paint specialists took care of the chassis and exterior of the classic car, the future automotive mechatronics technicians focused on the drive, battery, and chassis. In the rear of the "Prince," where a two-cylinder gasoline engine with 30 horsepower (22 kW) used to clatter, now hums an electric motor with 240 horsepower (176 kW). It comes from a 2020 Audi e-tron. The machine is powered by a battery from the Plug-In Hybrid Audi Q7 TFSI e quattro.

The battery? In the "trunk" at the front

This sits under the front hood, where the Prince once had its fuel tank. The electric racer breathes cooling air through a wide air intake at the bottom of the bumper and exhales it through a generously sized opening in the front hood. The tailgate also improves cooling and can be secured in a half-open position as it once was. This not only reveals the electric power center but also recalls historic racing cars based on the sporty NSU Prinz 1000. Where a row of open carburetor trumpets usually revealed the sporty intentions of these cars back then, today the electric motor of the EP4 is visible.

Lower and wider to bring the power to the street

For the apprentices, it was clear: their EP4 should show with pride that it began its life as an NSU Prinz. Therefore, the body was only subtly modified. The apprentices freed the sheet metal from rust and painted it in the Audi colors Suzuki Gray and Brilliant Black. Accents like the anniversary script "150" are applied on the side of the vehicle. The significant performance increase required extensive changes to and under the sheet metal.

The chassis comes from the Audi A1

A modified chassis from an Audi A1, including brakes and axles, forms the basis. The apprentices have mounted the extensively modified and noticeably broadened body onto it. The muscular fenders, unmistakably athletic, stand out. These were designed by the apprentices with the support of Audi Design and made real through 3D printing. Underneath, wide wheels find their place. Thanks to modern performance tires, they provide the necessary grip during acceleration and sporty cornering. Cynthia Huster, a trainee painter, explains:

“Looks matter! We wanted the EP4's performance to be visible from every angle.”

This is particularly true for the rear wing painted in signal yellow, which gives the EP4 a particularly dynamic look. The special feature: it is not mounted on the outer body like other vehicles but on the roll cage. Its supports therefore go through the rear window.

The interior: sporty and minimalist

Inside, the roll cage in signal yellow sets striking accents. Apart from that, the interior is reduced typical of motorsport; all other painted surfaces inside are black. The occupants sit on "Recaro Podium" seats.

A single-board computer along with the associated screen takes over the functions of the instruments and displays. It serves as both the speedometer and the vehicle's onboard computer, handling diagnostic tasks as well.

In all the steps of their work, the apprentices applied the knowledge they had gained during their training. Timo Engler, Head of Vehicle Technology/Logistics Training, explains:

“The project gives our apprentices the chance to work freely with different techniques and materials.”

So, alongside the electric drive, they also used 3D printing, a second future technology. Additionally, they used carbon fiber – known from motorsport – for the front hood. But the apprentices learned a lot not only in technical skills. Engler comments:

“For the EP4, not only was the vision very ambitious but also the time planning. It's great to see how the young talents have grown with their task and what developmental leap they have made as a team.”

Not least, the apprentices could always get tips and support from Technical Development. In this way, they automatically learned a lot about processes at Audi as well as got to know various contacts in other corporate areas. Audi's HR board member Xavier Ros was enthusiastic about the special project.

“With great commitment and a lot of creativity, our apprentices have realized a great vehicle. They can truly be proud of this result.”

And he continued:

“Such projects show that our company has a strong future with its young talents.”

What does this mean?

The Neckarsulm site, originally founded as NSU, is proud of its roots! NSU was once the world's largest motorcycle manufacturer and the NSU models have made history. With its charm and electric powertrain, the EP4 is intended to build anticipation for the upcoming all-electric chapters in the history of the Audi site in Neckarsulm. Why not start with an affordable entry-level prince for 25,000 euros?