Saab 93 conversion

[PaulHeystee]

Hi,
I started with my project; converting my Saab 93 cabrio to electric with the use of Nissan Leaf drive train and battery.

It looks like it will fit straight in. I can use the original motor mounting point of the Saab, albeit with some small adapter plates.

As soon as I have more details I will share it.

[m.art.y]

Oh wow that's cool my ex favorite automaker. Had both 900 OG and 9000 anniversary. If I still had the 900 it would have been a perfect car to convert to replace the weak gearbox. That leaf stack is similar shape to the original 93 engine. Good luck

[PaulHeystee]

More pic; an update.

The relay from the Leaf battery went under, in the tunnel where the exhaust was.
I had to relocate the engine stack as it was sitting too low. I matched the halve shafts Nissan/Saab and cut them to length. Welled them together with a small tube, when they are performing well I will have some made (without welding)

Next are the wire looms for the motor and computer. I think I will also add an small controller taking CAN bus messages from the motor stack, to control the original Saab dashboard; the rev counter will be an 'amp meter' where amps drawn are shown. My idea was to keep it on steady 2.000 rpm as zero point, more rpm will show more amps usage, less then 2.000 rpm will show regen.

The old battery charge (12 volt battery) lamp will be the HV charge in progress light by letting it blink.
I will need to change the dash board and replace with one from an automatic to be able to show when the system is in D N or R mode. I already have a modified automatic gear shifter ready, with switches.
Fuel level => SOC, however, in the first 5 seconds after starting it will show SOH.
Temp => coolant temp, like before. I need to figure out if I have to change the resitor value so it will not show low all the time.
Oil pressure lamp => not needed

The road speed is taken from the ABS computer and works autonomously, so no need to modify. road speed is taken from the left rear wheel ABS sensor.

[johu]

Really like that bracket that takes the HV connector and contactor assembly.

Of all cars I wouldn't have expected a Saab to accommodate that Nissan charger! Does it really fit?

[Dusty4]

Nice work, looks like a high quality build.

[PaulHeystee]

Really like that bracket that takes the HV connector and contactor assembly.

Of all cars I wouldn't have expected a Saab to accommodate that Nissan charger! Does it really fit?

Yes, it fits, both under the haube als under the car, nothing sticks out. Even the location of the differential is spot-on.

[PaulHeystee]

It's done!, well 99% at least.
Yesterday I drove my Saab for the first time (A to B) and all went well, covered 91 kms without any problems.

I used the ash tray to accommodate the small display that shows SOC and drive mode.

It is pretty fast, not ludicrous fast but just fast, as Saabs should be. The cruse control also works (the unit with the cable controlling the throttle)

[jnsaff]

Congratulations! Well done! Is it also road legal and registered as electric?

[PaulHeystee]

Thanks!
Step two; getting it road legal. Big advantage; no road tax when 'fuel' is 'electric'
I am driving it with 'car dealer/test drive' number plates at this moment.

[PaulHeystee]

However, i am still struggling with the charge socket, I have type 1 but want type 2. Not so straight forward as I thought.

It is charging through type 1, original Nissan Leaf. Even the ChaDeMo fast charger is working.

[maok]

Congratulations on your successful conversion Paul.

I am also looking to do a Saab with the Leaf motor stack, however mine is a '88 900 turbo.

Do you know if the onboard charger of the Leaf can charge a battery pack much less than 360volts? I am looking at a pack about 240volts, ie 10x Model S modules.

Regards,
Moe from Brisbane, Australia

[EdvartsW4E]

pretty sick, love Saabs and this project looks cool. More pics of the conversion (battery pack, etc.) or is there a tread somewhere?

[PaulHeystee]

The battery is located under the rear seats. Partly sunken so it just sticks out at the hight of the original foam.

[johu]

Great fit! Will you have some raised rear seat?

[EdvartsW4E]

Is it a leaf cells? Seems like a good distance on such small pack

[PaulHeystee]

Yeah, the complete set of cells, incl BMS. I removed the seatbelt fixings because I though it would not be allowed to have two people seated on top of it, but at the authority check they said, if you'd left the seat belt fixings it woul be allowed (!)
The next Saab 93 I will do(with 160 kW Leaf stack, will have them kept in place, for sure.
I am looking into the Peugeot/Stelantis 50 kWh battery for this next conversion. I have some BMS options and a Leaf BMS emulator so the Resolve controller will work.