I think I've hit on my water cooling solution. I've found aluminum cooling blocks for (relatively) cheap. I can use 4, 5 or 6 of them in series to fit my battery pack designs. I've also found this as an AC-to-water heat exchanger, so I can keep the batteries below ambient when charging and on hot da...

I was recently contacted by a rep from Advantics. They have a developed CCS charge controller for 1600 Euro. Expensive, yes, but it looks like it's a fairly small form factor and there's no amperage limit for CCS charging. Here are the videos they shared with me: https://youtu.be/hAjZhExmDhM https:/...

Currently working on the water cooling. I've been quoted $2500 per unit (I need 7) so that's a no go. I'm trying to find an off the shelf solution that will work, as well as semi-custom solutions. This is the last major problem to overcome for the battery packs. I have several irons in the fire on t...

As a not-very-educated-in-electronics person, I'm deeply interested in purchasing whatever shortcuts to CCS charging goodness I can get. Seems like most people on here are in Europe. I sincerely hope there's a CCS type 1 adaptation that can be had using this method. Does anyone know if CCS type 1 an...

Thanks for all your hard work on this, guys. I wish I had your technical skill in this area. Alas, my talents lie elsewhere. I will happily work with someone to hammer this out once my build gets to the point where it's self-mobile and charging with a J1772 connector. I happen to live less than a mi...

Quick update, the first two battery boxes are out for fabrication. They will both fit under the hood. 124 two-pack modules total.

Looks like an Orion BMS 2 108 port version will serve well. Each battery box will have it's own port, with 30, 32, and 36 leads respectively.

Wohoo! I got my new drill press and it works like a champ. Makes the aluminum holes at 500rpm without any binding, tearing or any other issues. IT's also faster as I can put more weight on the handle. I went from a 5A model to a 13A model and it makes a huge difference. I think I have enough cut, dr...

A few updates. Ran into a few more production snags - like my poor old drill press blowing through capacitors, forcing me to order a new one every time it happens. I've ordered a much more powerful one (13A vs my little 5A) that should remedy that particular problem and speed up my drilling besides....

I would take a look at SendCutSend.com for those aluminum pieces. I use them for quite a bit of my custom fab stuff that I want to *not* look like I made it with pliers and a dull hacksaw. If you have that many to make....automate it for sure. I've got everything set for mass production now, and i ...

The cruel math of building a custom battery pack I'm using 3"x1/2" 6061 aluminum to build connectors for the batteries I'm using. Since I'm using tabbed batteries, I'm making ends that compress the tabs together using long machine screws to hold everything in place. Each end unit requires ...

Limited to 200A = 70-80kw. Interesting. Likely a limitation of the contact rating. Seems like Kona/Niro are at the same limit (77kw); ID3 does 100, Bolt is down at 55kw. I own a Kona EV. At 77kw, that's about 1.25C on the pack, but only to a 55% charge. From what I can find on the Kona batteries, 1...

clanger9 wrote: ↑Tue Dec 08, 2020 6:23 pm That's going to be an epic conversion. Cool spec

Either that or an epic fail. Either way I'll get a good story out of it.

Go big or go home, right?

The story so far: My daughter (who is still a ways away from driving) came to me with the idea of converting a "cool car" to electric. After some research, a Porsche 944 seemed to be a good fit. We talked about it and came up with a rough game plan. Here's a basic rundown on where we start...

Hey folks. I've been looking for a not-ridiculously-priced way to CCS fast charge my 944-E project car. I also happen to own a Kona EV. The thought of the charge controller for a Porsche coming from a Hyundai tickles me immensely. I have to warn anyone using this part that the charging pattern Hyund...