Did you see what @Windraver did for this on DIY Electric Car? 3D printed covers used to connect on top. I know you said you wanted to avoid that, but might be food for thought and he shared his files.

https://www.diyelectriccar.com/threads/1986-crx-ev-conversion-nissan-leaf-donor-mr-conversion ...

Simpsons did it :)

As this is basically a reiteration of something that exists, why not take a look how one implementation has been made and see how to adapt/improve the design from there?

https://inductiveauto.com/product/nissan-leaf-em57-full-hv-wiring-kit/?srsltid=AfmBOoosot11Fr5VBB2f3yDWf ...

Vaguely planning...

https://ceravyn.net/up/VW/Screenshot%202025-06-26%20at%2013.18.27.png

Would something like this be outrageously dangerous for the EM57 phase connectors?

I'd much want to avoid putting anything on top of the motor now (where the phases typically stick in from) as the space is ...

The Tesla M3 PCS is NOT waterproof, so I would re think its location and house it in something.


Thanks for the heads-up! I'll probably end up doing a sort of floor/thin weathershield panel covering the empty area around the motor to keep the motorbay a bit dryer in general. We'll see. :)


I ...

Getting back to this. 😊 Final mount sandblasted, powder coated. Motor has been mounted!

https://ceravyn.net/up/VW/IMG_9529%20Large.jpeg

https://ceravyn.net/up/VW/IMG_9528%20Large.jpeg

3D-printed some endcaps for the crossbar to keep dirt and dust out. With my own Ceravan logo, of course ...

Yeah I'm currently thinking of a set of 90deg busbars towards the middle of the motor, enclosed safely in some 3D printed case, then 50mm2 cables to inverter. not too worried, I'm sure this can be made to fit somehow.

With our plasma cutter back in operation it was pretty quick to cut the pieces for the upper mount as well.

Tackweld together for test fitting.

https://ceravyn.net/up/VW/IMG_7769.jpeg

Confirmed it fits *almost* perfectly. Well. It fits, but something needs to be done to this water line which ...

Very nice motor mounting! Looks very professional!

by the way; I am working on a controller that can operate the small park acuator motor on the Leaf gearbox.
As soon as I am finished testing it I will place a post.


Thanks! 😊

This would be great!! I've been thinking about how nice it'd be to ...

Hell yeah motor is in!

Are you using stock axles too or did you need longer ones?

m3 battery modules: the threaded terminal posts are quite long. I cut mine down so I was able to tightly pack modules together. And just made a clamp to junction the hv cable


🥳

Yeah stock CV's with your stubs ...

Rights, enough practice and time to tackle the proper pieces! 😎

https://ceravyn.net/up/VW/signal-2025-03-22-122924_002.jpeg

https://ceravyn.net/up/VW/signal-2025-03-28-202215_002.jpeg

https://ceravyn.net/up/VW/signal-2025-03-30-133659_002.jpeg

In the end I ended up quite liking TIG welding ...

I modelled these in Solidworks and have all the DXF's I can share if useful. I had them profiled from a cheaper plastic so the cut edges weren't great and I had to do some filing at corners. I'd go a more rigid PTFE or similar to get a good cut edge as the parts slot together to form the assembly ...

I battled with a range of module mounting options for these too. Some detail on ideas I had to try reduce parts and complexity:

https://openinverter.org/forum/viewtopic.php?p=35408#p35408


That's a wildly different approach to the same problem, heh. :D I do like it! You don't happen to have ...

Battery box, 5th iteration:

https://ceravyn.net/up/VW/Screenshot%202025-03-11%20at%200.20.00.png

These Tesla M3 modules are pain to work with but I think I've finally come up with a design which allows mounting them from their original mounting points (the only load bearing structure on them are ...

I think I'm going with it as is (at least well, todays mood, but the steel shop is closed 'till mondays so here's whole weekend to overengineer this still! 😂 ).

It does show max. displacement and twist/bend but I've set it to "show actual" instead of exaggarated so it's not that visible in the ...

Yeah I don't know. 😄 I'm just a lousy paramedic, not a physics person. 😂

I made is stronger just to be sure. This is stresses with the improved design. 2223Nm torque + 1000N downward force.

https://ceravyn.net/up/VW/Screenshot%202025-03-07%20at%2019.06.02.png

So replaced the L-profiles with ...

The torque at the wheels acts through the driveshafts and is opposed by the transmission mounts.
You are thinking of the torque between the motor and transmission.


I've spent the whole morning thinking of this and still ain't sure. 😂 In my mind:

Yes torque (280Nm) is generated by the motor ...

Hmm. I need to double check this with fresh brain tomorrow. It's way too late for physics here.

Correct me if I'm wrong, but doesn't the gearbox gearing reduction affect the forces experienced at the drive shafts but does not change the reaction torque at the motor mounts?

Say 3:1, the drive shafts experience three times the engine torque, but the motor mounts can only ever react to the ...

Didn't realise fusion could do this. Maybe I'll need to have a look at modelling my designs in it. Which motor mounts are you using? I'm currently looking at my options.


I contemplated pretty much every stock option available but in the end I bought the original 1600cc engine rubber mounts. So ...

Hmm. Some more Youtube videos later I now know how to use Fusion simulations. That was surprisingly easy and convenient. 😎

With simulation (S235 steel) 3mm L-profile shows to be "fine" but ~1.6 SF

https://ceravyn.net/up/VW/Screenshot%202025-03-06%20at%2013.57.11.png

But nevertheless I decided ...

Still working on this. 8-) slow & steady.

Quick update about motor mounts.

This is my current plan:

https://ceravyn.net/up/VW/Screenshot%202025-03-03%20at%2016.59.41.png

https://ceravyn.net/up/VW/Motor-assembly-v11.mp4

Lasercut templates from clear acrylic to check that everything fits ...

Nice to hear from you! It’s been quiet on your build page, but I hope you’re making progress. I was impressed by your repair and restoration work so far. If you want a competition, I bet my non-existent welding skills are worse than your non-existent welding skills :) But then I’m not aiming to do ...

Just popping to say hi

I'm struggling a lil with engine mounting due to my limited (nonexistent) welding skills but my build is still coming along slow and steady. Happy to hear my posts in DIYelcar had inspired you too, hehe

Best of luck with your great work!

- Sara

Slightly related to this subject, but is that "common retaining ring" a standard size for most drive axles and where do people normally buy those? :D I get that this is a silly question but all I've managed to find is those thin washer like snap rings, not the ones which look like they've been made ...

Time for some updates again :) it's going to be a long and picture heavy one. :D

Normal restoration stuff is still taking most of the time, but now I have windshield, doors, dash, seats and all the car stuff mostly in place. 😄 Now it looks like a proper car!

https://volkkaripalsta.com/keskustelu ...