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.

Nice work, should make it a bit easier to retain parts of the stock bus bar layout. You'll likely never run that fan with a huge radiator like that ;) Yes indeed, I actually bought a new factory bus bar from Nissan to use which makes it so much easier and tidier. That's my thoughts about the coolin...

Making progress. 2nd box is now coming together. Each box will hold the same number of battery modules but the driver's side will also house the BMS, contactor box, connectors, and fuse which is why it's wider. https://i.imgur.com/ClREe5r.jpg https://i.imgur.com/V9oE7w1.jpg The two stacks are shorte...

Nice! I'm working on a similar box right now. What are you welding with? How's it feel to weld, compared to steel? I bought a secondhand Miller 180 that included a spoolgun setup. I am using 5356 wire which was recommended to me. I did a class at General Air to get a feel for it and of course Youtu...

Made some progress on the battery box. My buddy, Woody of Electromod Garage let me use his plasma table to cut up some aluminum. That thing rules. Used 5052 1/8" for the sides and 1/4" for the bottom and end plates. His table cut the parts absolutely perfect. Super pleased with the results...

Nissan LEAF pumps work on 12v only and are really quiet. They have 3/4 fittings. I think they are the same as Tesla pumps, not 100% sure.

I'm looking for the large bus bar for the rear stack in a Nissan LEAF pack and also some of the steel angle braces inside the pack.

Thanks in advance!

Looking forward to seeing your project progress. This will make a great conversion. Two things: the 24kwh pack might be tough to get 60 miles out of. They also are all probably badly degraded by now. I have a LEAF 30kwh in my Land Cruiser which is about the same size as your Rover and I get about 60...

Sure, right now what I have now is definitely a rough draft, and would need some cleanup and safety added depending on the application. Ok cool, I would be interested in a drop in board that would be compatible with the Resolve-EV controller, which uses OEM CAN commands and wiring. 2 boards at firs...

Are you interested in making more of these?