'70 MGB Roadster - 2015 Leaf EM57 powered

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Re: '70 MGB Roadster - 2015 Leaf EM57 powered

Post by 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!
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Re: '70 MGB Roadster - 2015 Leaf EM57 powered

Post by Kevin Sharpe »

mike77cos wrote: Mon May 04, 2020 6:54 am 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
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Re: '70 MGB Roadster - 2015 Leaf EM57 powered

Post by jerrykco »

I was all set to register for a class but then COVID19 happened. Maybe next year?
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Re: '70 MGB Roadster - 2015 Leaf EM57 powered

Post by Kevin Sharpe »

jerrykco wrote: Mon May 04, 2020 2:51 pm 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
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Re: '70 MGB Roadster - 2015 Leaf EM57 powered

Post by 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
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Re: '70 MGB Roadster - 2015 Leaf EM57 powered

Post by kiwifiat »

Nice job, now time to get the motor into that beautiful MGB.
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Re: '70 MGB Roadster - 2015 Leaf EM57 powered

Post by PacEmaker »

jerrykco wrote: Tue May 12, 2020 12:26 pm Throttle working.

Video of throttle test.
https://www.dropbox.com/s/2msdfpkep33nk ... e.mp4?dl=0
Very pleasing to see Jerry!
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Is this smoke trying to tell me something ... :twisted:
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Re: '70 MGB Roadster - 2015 Leaf EM57 powered

Post by 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.
IMG_5910.jpg
IMG_5909.jpg
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Re: '70 MGB Roadster - 2015 Leaf EM57 powered

Post by 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.
IMG_5913.jpg
Christopher working on the Stick Shift removal.
IMG_5919.jpg
Houston, we he have a stalled lift off.
20200517_161548.jpg
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Re: '70 MGB Roadster - 2015 Leaf EM57 powered

Post by 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.
OrigAdapterDesignPlan.jpg
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.
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Re: '70 MGB Roadster - 2015 Leaf EM57 powered

Post by jerrykco »

Next we made changes to the Adapter plate to have a ring connector (yellow above) that hold both bearings:
Adapter Plate-HM.jpg
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Re: '70 MGB Roadster - 2015 Leaf EM57 powered

Post by jerrykco »

Test fit of the Adapter Plate on the Leaf Motor
Adapter Plate.jpg
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Re: '70 MGB Roadster - 2015 Leaf EM57 powered

Post by jerrykco »

And next the complete adapter on the Motor, ready to put in the MGB to start the motor mount install.
20210110_144552.jpg
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Re: '70 MGB Roadster - 2015 Leaf EM57 powered

Post by 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.
IMG_0771.JPG
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Re: '70 MGB Roadster - 2015 Leaf EM57 powered

Post by jerrykco »

And ta da. It's in.
Front View
IMG_0779.JPG
Rear View (And more detail on the rear mounts)
IMG_0778.JPG
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Re: '70 MGB Roadster - 2015 Leaf EM57 powered

Post by 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.
Spring Over Shocks.jpg
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Re: '70 MGB Roadster - 2015 Leaf EM57 powered

Post by SuperV8 »

jerrykco wrote: Tue Jan 11, 2022 10:47 pm 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?

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Re: '70 MGB Roadster - 2015 Leaf EM57 powered

Post by jerrykco »

Hi Tom, Thanks. Yes there is no transmission.
Here is what I used to calculate the rpm vs speed
CalculatedSpeed-MG-with-Leaf-EM57.jpg
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Re: '70 MGB Roadster - 2015 Leaf EM57 powered

Post by jerrykco »

And this for the Torque for the Leaf EM57
Torque-RPM-HP-Curve-Leaf.jpg
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Re: '70 MGB Roadster - 2015 Leaf EM57 powered

Post by 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.....
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Re: '70 MGB Roadster - 2015 Leaf EM57 powered

Post by jerrykco »

Continuing the progress report.
My next step was to build a second 24 module pack from the two 12 module battery packs. I plan to mount them cross ways to the frame. One in the trunk and one behind the seats. I located a buss bar from someone that just sells the modules online. And using info from Wolftronix.com rewired the pins from the Buss bar BMS connections to match the 12 module bus bars.
1. Remove the buss bar and disassemble the 12 Module packs.
20211213_172846-Copy.jpg
2. Stack the modules onto the 24pack frame rods. NOTE Pay attention to polarity. I made a mistake and smoked the BMS!
BatteryBuild-24-module.jpg
3. Layout the bus bars
20211215_072321-Copy.jpg
4. Disassemble the connectors from the 12 pack and from the 24 pack buss bar. Map out the BMS Connections for the 12 packs. One has a 32 pin connector the other a 24 pin connector. Using a tine flat head screwdriver you can remove the face of the connector and pop the keeper up (see pictures.
20211220_081146-Copy.jpg
pop open the connector keeper
20211220_080853-Copy.jpg
5. After that you can map the pins coming from the 12 module packs. Here is my map. But as I said I smoked my BMS. I think it was how I stacked the modules. I should have started in the opposite polarity. Anyway you should always validate your work before connecting your BMS.
Bus-Bar-Pinout-Setup-12-to-24-ModulePack..jpg
6. To pull the pins from the 24 pack you will need a safety pin (large Diaper pin). Look at the face of the 32 pin connector. Each hole for a pin has a lock at the top of the hole above the pin. Using the Diaper pin you can stick it into the hole from the face, above the pin at an angle (down towards the pin) catch the lock and lift it. Then pull the pin out the back. Once you have them all out you can reinsert the pins into the proper holes.
20211222_112902-copy.jpg
7. Now attach the modified (for the BMS) busbar back to the newly constructed 24 module pack
20211217_081805-Copy-Rotated.jpg
20211217_081805-Copy-Rotated.jpg
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Re: '70 MGB Roadster - 2015 Leaf EM57 powered

Post by jerrykco »

I purchased my replacement BMS and am waiting for it to arrive. While I wait I am going to disassemble the new 24 module pack and try to see where I screwed up.
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Re: '70 MGB Roadster - 2015 Leaf EM57 powered

Post by SuperV8 »

jerrykco wrote: Wed Jan 12, 2022 7:27 pm Hi Tom, Thanks. Yes there is no transmission.
Here is what I used to calculate the rpm vs speed
CalculatedSpeed-MG-with-Leaf-EM57.jpg
Hi Jerry,
Looking at the Leaf it has approx 24.8" tyres - so not too different from the MGB 24.5" so no real gearing advantage of a smaller tyre so we can ignore tyres for this fag packet calculation:

From what I can see the standard MGB 1.8 engine has approx 100ft lb max torque - which is 135Nm.
Using your final drive ratio of 3.45:1 and 1st gear ratio of 3.5:1 that gives a transmission total gear reduction of 12.08:1 - which multiplies your engine torque x 12.08 which is 1630Nm available at the wheels.
Wheel torque:
1st = 1630Nm
2nd = 1025Nm
3rd = 638Nm
4th = 466Nm

Although the Nissan Leaf motor quite a good max torque of 280Nm, and as you're only using the diff reduction gear ratio of 3.45:1 you can multiply 280x3.45 = 966Nm - so that would be the pulling power of the original 1.8 somewhere between 2nd and 3rd gear.

The Nissan Leaf gear reduction of 7.94:1 would give you a wheel torque of 2223Nm! which is what makes it feel 'sprightly' off the line.

One of the many benefits of electric motors is much higher RPM's - 10,300max for the Leaf motor - which means you can use gear reduction to increase torque available at the wheels and acceleration.

From this paper you can see the leaf motor efficiency suffers when at high torque and low rpm:
https://www.energy.gov/sites/prod/files ... 2013_o.pdf

I hope you don't mind me commenting, it might work fine - what do I know, I haven't yet built an EV! only in my head :?
There are lots of people using the Leaf motor attached to a gearbox - so having no reduction gear would be effectively like driving all the time in 4th (normally 1:1. Maybe this work's ok? maybe someone can comment how it is in the 'real world'! sure it would be fine cruising along, but might struggle with hills?
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Re: '70 MGB Roadster - 2015 Leaf EM57 powered

Post by johu »

I usually drive that heavy Touran around in 3rd which I consider quite agile. In 2nd gear it is a real blast and traction control still kicks in around 60 km/h. In 4th gear it is well drivable, goes up steep inclines and just feels a bit sluggish off the line. So if you don't feel the need to show everyone that EVs are faster off the stop light but rather enjoy cruising, you should be fine with only the diff ratio.
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Re: '70 MGB Roadster - 2015 Leaf EM57 powered

Post by SuperV8 »

johu wrote: Thu Jan 13, 2022 10:45 am I usually drive that heavy Touran around in 3rd which I consider quite agile. In 2nd gear it is a real blast and traction control still kicks in around 60 km/h. In 4th gear it is well drivable, goes up steep inclines and just feels a bit sluggish off the line. So if you don't feel the need to show everyone that EVs are faster off the stop light but rather enjoy cruising, you should be fine with only the diff ratio.
Interesting real world feedback!
So should be fine as is - if you want to go chasing MGBV8's consider a gear reduction :)
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