'70 MGB Roadster - 2015 Leaf EM57 powered

[jerrykco]

If you're not doing so already I recommend you use Damien's HV current limiting technique using a bulb or cooker element. I'm sure one of his videos will show you how

Thanks Kekvin, If you are referring to limiting current during the pre-charge a few seconds, I have created this two relay circuit which I manually control by first closing the pre-charge relay that has a 100 Watt 100 Ohm resister in line to charge the inverter CAPs, closing the High Current/High Voltage Contactor, then opening the pre-charge relay.

[Kevin Sharpe]

Thanks Kekvin, If you are referring to limiting current during the pre-charge a few seconds, I have created this two relay circuit which I manually control by first closing the pre-charge relay that has a 100 Watt 100 Ohm resister in line to charge the inverter CAPs, closing the High Current/High Voltage Contactor, then opening the pre-charge relay.

No, I was referring to testing with a current limiting device in the HV line. This is useful while in the early stages to prevent a calamity if you've got anything wrong with your setup. I'll try to find one of Damien's videos showing the cooker element in use.

[jerrykco]

I made some more progress (Kind of indirect but part of the overall project).
I purchased a used single post lift from a nearby heretofore unknown neighbor who advertised it.

And over the last few weeks I also obtained some parts to build a DC Charger.
Parts were found on Ebay.
I ended up getting a 35AMP 240VAC Variac. I also purchased a 240VAC to 480VAC Transformer. Then I got a Bridge Rectifier and big Cap for a filter.
I assembled the parts and I was able to see I could get OVER 500V DC out at full Variac Voltage in.

Today was first attempt at charging the Leaf 24KWH pack. Success. I set the Variac so output level was 3 volts lower than pack voltage and slowly rased the voltage until I was putting in first 5A then 6.5A. I let it Charge for an hour and raised the Pack voltage 10V from 363 to 373V.

I started out with the Pack at about 21% SOC. And finished (today's short 1 hour charge) here.

[mike77cos]

What a great project

[jerrykco]

What a great project

Thanks. It is a whole learning experience.
Brief video charging.
https://www.dropbox.com/s/hsdiy1jq45oyx ... 0.mp4?dl=0

[mike77cos]

I'm lurking, just thinking I want to do a conversion, but I literally have no idea what to start with, or how to start!

[Kevin Sharpe]

I'm lurking, just thinking I want to do a conversion, but I literally have no idea what to start with, or how to start!

Would this help?

viewtopic.php?f=15&t=491

[jerrykco]

I was all set to register for a class but then COVID19 happened. Maybe next year?

[Kevin Sharpe]

I was all set to register for a class but then COVID19 happened. Maybe next year?

We've just published an update

viewtopic.php?f=15&t=491&p=10387#p10387

[jerrykco]

Throttle working.
I had this problem pointed out to me that I was not using the correct Parameters for a LEAF install.
I knew I had downloaded it but I failed to save it to Flash so the next time I powered it on it was gone and I didn't catch it.
SO when you get the parameters you like, don't forget to save it to flash.
Video of throttle test.
https://www.dropbox.com/s/2msdfpkep33nk ... e.mp4?dl=0

[kiwifiat]

Nice job, now time to get the motor into that beautiful MGB.

[PacEmaker]

Throttle working.

Video of throttle test.
https://www.dropbox.com/s/2msdfpkep33nk ... e.mp4?dl=0

Very pleasing to see Jerry!

[jerrykco]

Started the the removal of the ICE in the MGB. My son and my grand kids helping.
Got all fluids drained.
Disconnected all the various electrical and mechanical connections to the engine.
Removed the the front motor mount bolts.
We are now ready to lift the car and start underneath with removing the exhaust etc before lifting the motor out.

[jerrykco]

Day two on ICE removal. More progress. But no cigar yet. The Engine hoist needs more jack oil.
Great help again from my son Keith and my grand kids.

Regina removing the cross member under the transmission.

Christopher working on the Stick Shift removal.

Houston, we he have a stalled lift off.

[jerrykco]

Have been slowed down on this project over the past year but I have made some progress and have some new things to report.
After the ICE removal, next was designing connecting the motor to the rear end.
First step: Adapter Plate. I started with Jeff Black's adapter plate and redesigned it to eliminate the transmission, mount to the motor and connect to the drive shaft.

Working with Horizon Machining in Berthoud, CO this changed a little and I am working with them to get an updated drawing.
Suffice to say we decided to add a second bearing next to the motor so the drive shaft cant add aide forces against the motors shaft.

[jerrykco]

Next we made changes to the Adapter plate to have a ring connector (yellow above) that hold both bearings:

[jerrykco]

Test fit of the Adapter Plate on the Leaf Motor

[jerrykco]

And next the complete adapter on the Motor, ready to put in the MGB to start the motor mount install.

[jerrykco]

Here you can see the two added side motor mounts (Right and Left side of the motor) and the front motor mount With a welded Bolt.

[jerrykco]

And ta da. It's in.
Front View

Rear View (And more detail on the rear mounts)

[jerrykco]

Next I added Rear Coil Over Shock Kit. The original Hydraulic Shocks had long since failed I assume because This car had standard shocks with top and bottom mounts added when I picked it up. But I did have to remove the bottom mounts and flip and reverse them to get enough length to fit the Baha VW Coil Over shocks. In this picture you can also see the custom extended Drive Shaft attached to the rear end.
To get the length, I installed brand new hangers that prevent the rear axel from dropping too far. then measured the distance to the motor shaft.

[SuperV8]

And next the complete adapter on the Motor, ready to put in the MGB to start the motor mount install.20210110_144552.jpg

This is a nice project but I noticed it looks like you are intending to directly drive the rear axle from the Leaf motor.
All BEV motors have a gear reduction, in the 2012 Leaf's case 7.93 to 1.
What is your rear differential ratio? I think most MGB's rear axle's were somewhere like 3.xx:1 and as this will be your only gear reduction you may find this setup has something like 1/2 the wheel torque compared to a Leaf, unless your tyres are substantially smaller?
Obviously you will be lighter than the leaf, so maybe this and with a smaller tyre dia this might work?

Tom.

[jerrykco]

Hi Tom, Thanks. Yes there is no transmission.
Here is what I used to calculate the rpm vs speed

[jerrykco]

And this for the Torque for the Leaf EM57

[jerrykco]

Looks like 0-3000 RPM full torque. at 3000 RPM car will be doing 55mph. At 5000 RPM 116mph. Not that I want to go that fast.....