Battery is fixed. I actually had one of the M6 bolts on the bus bar loose on cell #95! I also moved the BMS cell taps in the area just to be extra sure.

No more voltage spikes when charging or revving the motor. Glad I caught that!

Got some new alloy 16" wheels and Continental low rolling resistance tires. Happy to get some good rubber on there. The wheels look cool too and match the black and silver style of the truck. Overall the truck just looks amazing and the EV specs have so much potential. I'm going to focus on get...

I will be doing an interview with Dave, the owner of the truck, tomorrow. Post up any questions you have for him or about the truck in general. A couple facts about Dave: he is a retired high school shop teacher and wants to use the truck to get students interested in cars and EV conversions. He bou...

Just a couple pics

Wow, that's interesting. Wonder if some copper shielding tape would also help? Love the badge, nice that it works out being that it's all from the same brand! I'm going to try the ferrites because it's quick and dirty, but if that doesn't work I'll drop the boxes and try to re-route the cell taps. ...

Welp ran into a snag. Right now it's not causing any issues but maybe will in the future. I noticed the last three cells #94, #95, and #96 are fluctuating quite a bit while charging or running the motor. I know those two BMS taps run really close to the HV main negative cable in the battery box. At ...

The problem with EV fires is actually temperature. I sometimes wonder with my nonexistent chemistry experience if shooting the car with liquid nitrogen might help...? It would likely vaporize immediately but maybe cool it down as well....? I did see a "fire lance" that they drive as deep ...

Thanks Jimmy, I am friends with a Captain of a fire department with over 20 years of capitaning experience, he often times reminds me that firefighters do NOT put out car fires, yes I am talking about regular gasoline powered cars. He says everything on that car will burn including the metal. They ...

Cars have been catching fire for over a hundred years now. The difference is that firefighting techniques and technology like aqueous film forming foam have been invented to deal with auto fires. EV lithium battery fires offer a new challenge to firefighters. They basically have no strategy to deal ...

Got the front end together. Dave did an awesome job making the flip-up charge port doors. One on the right for J1772 and the one on the left will be for Chademo (Chademo not installed yet). The Nissan badge comes from the '19 LEAF and it lights up when the truck is on and also when it is charging 8-...

Some more updates. Everything is starting to come together! Dave is beside himself, he's so excited about how it's looking. He ordered some wheels and tires yesterday; some cool looking 16" wheels with low rolling resistance tires. IMG_20240425_101727.jpg IMG_20240425_101735.jpg IMG_20240425_10...

Just a few small updates. Dave got the bumper finished up. Blocked off the grill and LED driving lights installed. Then he painted the whole thing in rubberized texture (it's upside down in picture). He also installed new headlights with LED bulbs and turn signals. Lastly, got the DNR buttons put in...

Got the wires extended and powered up the truck again. Everything works and the battery is happy too. Time to turn attention to the interior and get it buttoned back up.

johu wrote: ↑Thu Apr 11, 2024 5:44 pm Very tidy install and great re-use factor!
Are you using the stock battery-to-drivestack cable as well?

Thanks! I am currently extending the battery-to-drivestack cable as we speak. It needs to be extended approximately 42 inches.

I got the modules loaded into the battery boxes and all the accessories like contactors, fuses, current sensor, etc. Boxes are sealed up and in the truck! I misjudged the height of everything so when I went to lower the truck down over the batteries I couldn't get it low enough, oops! I was able to ...

The temperature sensors are also in the orange bus bar pieces.

The current sensor is in the middle near the safety disconnect and looks like this:

The BMS is the rectangular metal and plastic box with 4 plugs. Then there is also a battery box harness that has the round 36-pin plug and connects to the BMS. The BMS cell taps are located in the orange plastic bus bar assemblies (purple and black wires). You can't really remove the BMS cell taps w...

I think there is more to the story of these Rabbits! The original electric Rabbit was actually called the Unique Mobility Electrek. The Electrek was BEV sold from 1979 to 1982 based on the drivetrain and suspension of a diesel Rabbit with a GE sepex motor manufactured in Colorado. The Rabbit Electri...

I think you're doing a damn fine job, Greg! Can totally relate to you and P.S.Mangelsdorf, I've ruined my own fair share of cars, working on the cold concrete of an apartment complex so I can make it to work the next day, or doing something dumb and hurting myself. Every EV converter that I've met h...

Got the battery boxes mounted in the truck! Had to cut some of the cab but otherwise they fit nicely. Less than an inch of clearance to the driveshaft, but it does clear!

I would have used a motorcycle LiFePo instead. I used one in a LEAF for over a year in CO winters (down to -20F).

One grinder for cutting one for grinding. That's how you know you're really fabricating.

Got the bus bars trimmed down and BMS wiring all finished up.

The attach file method is pretty poor on this website compared to others I've used.

Ok sure I can do that from now on. I am using the default add an image button on the post control panel with my own image hosting service, thought I was doing it right

Dang look at that! It's even got speed holes. Nice work.