[WIP] '96 Citroen AX Electrique - Leaf drivetrain Taycan battery modules

[CrAzY_DrIveR]

Hi, after converting my peugeot to lithium i found this car that is the one a was looking for all along.
This is a original NiCd car 120v 20x6v 100Ah batteries and a DC 27hp motor.

Check fitting

I can close the hood with 1cm to spare, but i still want to go up 5cm so i will try to cut and lower the pdm cover.

Input and advice welcomed and appreciated

[PaulHeystee]

Bom dia,
It looks like you have to move the PDM to an other location, for example in the rear trunk.
I fitted the complete Leaf stack in my Saab 93 without any problem, this was because the original engine unit was also relatively high.

From looking at your pictures, I think you could still fit the complete stack but I think you have to make some serious belly protection at the front.

[CrAzY_DrIveR]

hello PaulHeystee

It's not perfect but it will fit.
Cutting the top and replacing it with a flat aluminium sheet, and making a groove to fit the bonnet rib i can go up 3/4cm.
The motor will be the lower part of the car but not by much, maybe 1 or 2cm.

The batteries arrived yesterday, i wanted to use leaf batteries but there is no space for that so the taycan are more dense and will fit nicely.

So now that the money problem is gone (i have none), all we need is time

In a perfect world there would be a replacement bms that would communicate with the leaf vcu and the taycan modules,
but we are in the real world so i have to cut windows in the aluminium case of those expensive batteries.

See you later if i don't burn down the house...

[m.art.y]

Perhaps another solution is to cut a round hole in a location where those contacts of the BMS board are so you can solder your own BMS wires to them? Would save you exposing the cells themselves like that?

[arber333]

Perhaps another solution is to cut a round hole in a location where those contacts of the BMS board are so you can solder your own BMS wires to them? Would save you exposing the cells themselves like that?

Nope! There is much material there which can cause overconfidence at drilling. If your drill slips you are into the battery meat no time. Better to go around the sides. I took my Jag modules apart and i would rather not do that again.

Also be advised BMS connector is fused. This means using higher (m)amp rated BMS could burn the fuse.

[m.art.y]

I don't mean hand drilling. I just know somebody has done so - they made a hole so they can solder BMS wires right onto the PCB contacts. Since in this case crazy_driver does not seem to be dissasembling the modules completely I remembered this option. Could be safer later on rather than having all that contact area exposed. I think can be done safely on a controlled machine cutting in very slowly and employing a hoover to suck up all the dust. I may be wrong though

[arber333]

I don't mean hand drilling. I just know somebody has done so - they made a hole so they can solder BMS wires right onto the PCB contacts. Since in this case crazy_driver does not seem to be dissasembling the modules completely I remembered this option. Could be safer later on rather than having all that contact area exposed. I think can be done safely on a controlled machine cutting in very slowly and employing a hoover to suck up all the dust. I may be wrong though

True, if you have the mill, then you can have fine control over your blade. Maybe that would be viable.

[CrAzY_DrIveR]

This is just horrible to open, i understand why people just cut the complete side panel...

[CrAzY_DrIveR]

now i just need to find a laser welding machine

[CrAzY_DrIveR]

Taycan BMSLink installed

[johu]

Let me guess: shorting out adjacent pins makes the magic smoke leave the ribbon?

[CrAzY_DrIveR]

it should if you short it for long enough

[CrAzY_DrIveR]

[CrAzY_DrIveR]

Battery modules are laser welded and done after modification from internal bms to external bms with internal fuses.


Now time to make the battery boxes and 3d scanning with the kinect toy

Also check if the ldu fits, 80kw vs 400kw makes you think, but i can't afford a charger/bms/controller to make this work now.
Some day i hope to find a mk2 citystromer where it will fit nicely...