Thanks a lot for the quick feedback! This helps with a lot of things. :D

Front part of the car is pretty much all wired now, but the harness connecting the front and rear is giving me slight headaches from trying to plan everything while simulataneously feeling like I still don't understand half of ...

Doing Zombie wiring next. Looking for hivemind again. 😄

Basically I'm doing most of the 12V wiring as per original; using the existing wiring channel under the floor for running power feeds from the rear motor room to the front fusebox throughout the whole length of the vehicle. 12V battery lives ...

Heh yeah, we'll see. I'm watching "Understanding basics of canbus" and similar one after another currently, it's a long way 'till I'm up to providing useful feedback I'm afraid 😂 but who knows, maybe someday. :)

and don't get me wrong when I said I was hopeful there'd be more users at this point ...

I forget if you were planning to mount under the rear bench seat or under the bus somewhere. You should have the original VW mounting holes for minibus seats in the floor and the seat belt mounts on the angled walled behind that. That’s what I used as the basis for a frame for my box. Can’t ...

Hmm. Might also be getting 2nd (102nd, at least) thoughts about the battery pack.

The more I look the harder it seems to mount the M3 modules safely 😔 darn mechanical levitation!

That added to the imbalance issues some people have been having, BMS support, etc.

Currently as far as I understand it ...

SO. MUCH. WIRING.

https://ceravyn.net/up/VW/IMG_9790.jpg

Making the main harness.

12V battery, etc are located in the rear. Main fusebox is in the front below dash. I'm upgrading the original 1970's wiring diagram slightly.

- Adding main fuses (Midi 50A) to battery positive so no wire goes ...

Yeah I think this should be doable.

https://ceravyn.net/up/VW/Screenshot%202025-06-30%20at%2016.32.02.png

There's a protrusion from the motor case just below the rearmost phase in my setup, which necessitates longer copper and bolts, currently around 80mm length. Could shave off some 1.5cm from ...

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 ...