This thread might be helpful and the link from the first post:

viewtopic.php?p=51203&hilit=nkiernan#p51203

I have one on the bench at home so can grab some dims later this evening

Same, have a PCS that is working well on the bench and edging closer to installing it. It works neatly for me so will continue testing and monitoring for now

Transfer Case: The divorced transfer case input stub has caused some headaches along the way holding up that first wheel spin, so decided to try tackle this myself...but not holding my breath! Had spares for the transfer case spline (from a failed gearbox) and a CV flange. The gearbox output shaft ...

Still trying to get confidence in the GS450 design, as all my calculations suggest it will not be able to climb long hills at cruising speed (say mile long 4% hill at 65mph) as it will overheat To model or calculate accurate results takes in many variables, and could be a project in itself. After w...

Batteries: Getting back to the batteries, and there will be a link between the two battery boxes that requires the lower battery module in each box to connect to a junction box. Chance to repurposing some of the original TM3 busbars Bat019.JPG Bat020.JPG Bat021.JPG I've not tackled the damaged alu ...

HVJB:

So the Orion 2 BMS needs its own shunt too! Required a little trimming and tweaking to the main busbar to allow it to fit and some tidying with heat shrink

Does this relate to Zombieverter also, or might it in future?

I don't yet know if my shunt is faulty or I'm doing something wrong Just for the shunt, did you work through the few openinverter wiki articles for the shunt to test it separately from your system and prove its ok and configured as needed? https://openinverter.org/wiki/Isabellenh%C3%BCtte_Heusler h...

If nothing shows up closer to you I might be able to help but it would be shipping from Ireland!

I'm not really familiar with the Leaf BMS setup, but I had to deal with something similar for fuse and isolator locations using an Orion2 BMS with Tesla Model 3 batteries. There's a section in the Orion2 BMS documentation that explains what and why that helped me understand better. May not be releva...

HVJB: The high voltage junction box in the engine bay will house the Tesla Model 3 PCS (AC and DC charger and DC-DC unit), as well as connecting the battery to the inverter and charging interfaces, which means more connectors :roll: HVJB020.JPG HVJB021.JPG Originally I planned to hard wire the batt...

Inverter: Probably won't get very far with those spindly wires! These were used with the 48V bench test voltages Inv013.JPG Time for an upgrade and another matching connector that will also connect to the HVJB in the engine bay Inv014.JPG Inv015.JPG Inv016.JPG Inv017.JPG Inv018.JPG Inv019.JPG Will ...

Battery Boxes: Back to the junction boxes that will be integral to the two battery boxes. These looms connect both battery box junction boxes to the high voltage junction box in the engine bay and consists of the HV DC loom as well as the Orion 2 BMS tap wire loom and a contactor control loom with ...

VanGogh wrote: ↑Thu Jul 20, 2023 7:16 am Do you think the voltage on the start/stop button and the handbrake depends on the CAN bus signal or not?

Did you check if the start button for example simply closes a switch, so continuity between ground and start_stop_1 when button is pressed?

Pete9008 wrote: ↑Thu Jul 20, 2023 9:57 am How did you get on with the bms, were you able to repair that pcb trace?

Didn't get back to the trace repair just yet, hopefully soon

HV Loom:

Amphenol plug and socket kits arrived so had them assembled into two loom sections. Main one connects the two battery boxes and runs to the HVJB in the engine bay. Second one runs from the HVJB to the inverter

If you don't mind me asking - where did you get your welding table, was it in kit form or pre-assembled and would you recommend the supplier? I wouldn't recommend the supplier at all, doesn't know what he's at! :) It's one I drew up and fab'd myself, slot and tab design, and had laser cut locally. ...

Battery Boxes: Time to get the battery boxes finished up too. Adding a junction box to each battery box for access to contactors and pre-charge resistor and to mount the various connectors. Every time I sit and look at the layout it changes... but getting there now. There are some benefits to takin...

iPDM56 Controller: Love this unit. Got one of Celeron55's iPDM56 units for a host of I/O options and CAN buses. This is based on an Arduino Uno which makes it more suitable for my programming ability! The Zombie VCU programming is a bit more involved so this allows me to develop and test the logic ...

Cooling System: Settling on two coolant loops to cover both drive and charge modes. The RR has a neat auxiliary radiator tucked in front of the drives side front wheel so got a second one of the same radiators and two 8" pull fans , a set for each loop. Originally fit the BMW coolant pump but ...

Brakes: To get ready for the first drive :roll: it was time to go back and finish off some open tasks...brakes seemed like an important one! Had another type of brake vacuum sensor sitting around so tested some options looking for the cleanest solution BR003.JPG BR004.JPG BR005.JPG Glued the vacuum...

Wondering if anyone has identified a source for the Tesla Model 3 HV heater/AC connectors? Or if there is some info about how to disassemble and re-pin one!? Looks like this one got a little toasty on one of the positive leads. The cable entry and pins are at 90 degrees and the orange outer casing d...

This is an example of what I used (expected some issues with cheap emulators but so far so good it seems): https://www.ebay.co.uk/itm/175717846266?var=0&mkevt=1&mkcid=1&mkrid=710-53481-19255-0&campid=5338268676&toolid=10044&_trkparms=ispr=1&amdata=enc:1jXL5oLWETGCYZJHlsbQ...

Great to see an update and big milestone to hit