I found coolant in the Encoder Wheel area as well and there was a slight score on the rotor shaft pipe. I drained the oil in the gearbox and didn't find any coolant in the oil as it was also still red & clear. The inverter housing is also clean and dry. For rotor removal, can you remove the moto...

After a years hiatus from posting, I have a couple of new updates. The first is that the car is running well on a 300V-76 cell KIA SoulEV battery pack. It was originally a 400V-96 cell pack, but through some ignorant stupidity, I damaged two of the original four modules. The pack is controlled by an...

You are the second person I know who recently lost their DC/DC converter. The other DC/DC failure was it just stopped working. No smoke, no warning but just stopped reducing voltage. I'm starting to think that if they get too hot, they can fail sooner than later.

I admire the way you are always upgrading something on the car. I have a couple of questions: 1) I want to install a 12V inertia switch that will open the main & ignition contactors if there is a substantial impact. Can I power the Inertia switch from the Inverter 12V supply or should it be conn...

I am looking for a quick way to disconnect HV wiring from the battery to the main contactor box. I have been told NOT to use an Anderson Connectors due to the high currents involved under normal operation. I was looking at 600V welding cable connectors capable of handling up to 400 Amps. Any comment...

Quick question. I will be finally updating my firmware from 4.85 to the most current version (5.20.R). Can I do it directly or should I update the firmware in steps (ie 4.95.R, then 5.10.R, etc.) I noticed you used a hex file and STM programming application connected directly to the board instead of...

I liked the bolt-in cradle from F1moto because it fit perfectly into my Boxster space and left lots of room for a battery pack. It also came with two (2) drive hub adapters that were welded to a shortened Tesla drive shaft. If you are putting the car on the track, I would go with a fully machined dr...

Welcome to the "Club" What motor are you using? If its a Tesla, you will need to decide on a Large Drive Unit (LDU) or Small Drive Unit (SDU) This is important because the LDU needs to be installed to run backwards. For the LDU, you will need a revese oil pump and depending on the drive bo...

Yes Johnu, you are correct. I learned the hard way how NOT to test and operate batteries. I am making necessary modifications this winter to ensure everything is balanced before operating again with a new BMS.

Thanks for your replys on my issue. I do have the original BMS from KIA but I found it was only monitoring and not managing the cell voltages. I need to check my electrical connections.

Arber333 - are you suggesting to simply remove the damaged cell(s) and run on less cells?

Hi everyone. It's taken just under 2 years but I have completed the installation of a Tesla LDU into an 02 Porsche Boxster. The attached PDF takes you step by step through the teardown, experimentation/testing and final build. Be sure to watch the YouTube video at the end of the PDF. Enjoy.

I am also looking for information on these batteries. In September, I finished a project where I installed a Tesla LDU into an older Porsche Boxster. The car was powered by an 8 module 96 cell battery pack from a 2015 KIA Soul EV rated at 384V. I have been testing the maximum charging voltages and m...

Hi Jon. Do you have any units left to sell? I need one for my Boxster Tesla conversion.

Thanks for the feedback. I filled the casing up to the upper fill hole, which was recommended by another LDU enthusiast.
I will source the seals locally.

I have been test driving my Boxster Tesla conversion for a couple of week and have noticed oil on the concrete below the Tesla drive unit. The only source would be the gear reducer in the LDU. I don't have any leaks in the casing but I notice it very wet around the output drive shafts. Is any one el...

I'm not sure if this is the proper format to talk about a completed build using an LDU but I am quite proud of the final product. I also want to thank everyone who helped and assisted the build with suggestions on what works and what doesn't. Thanks again. Take a look at this YouTube video. https://...

Hi everyone. I have been driving my Boxster Tesla LDU conversion around the neighbourhood for the past couple of days and have put on about 10 miles (16KM). Everything is working well (so far). The car is using about 2-3 VDC per mile driven with starting and stopping at intersections. I have been wa...

I am about to upgrade my firmware from 4.85.R-sine to 5.13.R-sine. I have a hard copy of the existing settings that I know got the motor spinning. Is there anything else I should be aware of before upgrading the firmware? I am a little concerned because sometimes when I am working with the inverter ...

Just seeing the error message. I wasn't sure how to clear errors/faults. I'm just looking that up now.

Further Update to CURRENT LIMIT issue. I pulled the motor and the Inverter cover and saw no issues. IGBT's look good - no bubbles. The two green & one red LEDs on the Inverter Board came on and there were no lights on any of the 3 inverter phases. The Ign., Pre-Charge and Main contactors closed ...

It's old. 4.85.R-sine. I will be doing an upgrade this week if possible.

I am still having problems with the Inverter/Motor. Since my last post, I have made a few short trips around the bloc and everything was running well until the last trip. I had stopped at a stop sign and was slowly accelerating when the car bucked a couple of times and then no power. I had it towed ...

Thanks to everyone who contributed to this. Looks like the problem was operator error. The 12V battery was only putting out 10V. This is why the pre-charge contactor didn't close and why the UDC was not displaying full battery pack voltage through wifi. I connected a fully charged battery and got th...

Thanks for the replies. EV Builder - I will be measuring the phases tomorrow. If the IGBT's are damaged, can they be replaced? How difficult is this? I am hoping the issue is just the Open Inverter board. I am concerned that the inverter is damaged and the whole motor/inverter will need replacement....

I am having a problem with my Inverter. Here is the background: Tested motor/inverter on bench with 187V (1/2 the full pack). Wifi Open Source Interface confirmed voltages, current, etc. Mounted motor/inverter in car with approx. 220V batteries and did test runs forward & reverse in alley 200m-3...