[WIP] 1998 Nissan Frontier Minitruck - LEAF 40kwh

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Very tidy install and great re-use factor!
Are you using the stock battery-to-drivestack cable as well?

Thanks! I am currently extending the battery-to-drivestack cable as we speak. It needs to be extended approximately 42 inches.

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Got the wires extended and powered up the truck again. Everything works and the battery is happy too. Time to turn attention to the interior and get it buttoned back up.

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Just a few small updates. Dave got the bumper finished up. Blocked off the grill and LED driving lights installed. Then he painted the whole thing in rubberized texture (it's upside down in picture). He also installed new headlights with LED bulbs and turn signals. Lastly, got the DNR buttons put in the dash.

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Some more updates. Everything is starting to come together! Dave is beside himself, he's so excited about how it's looking. He ordered some wheels and tires yesterday; some cool looking 16" wheels with low rolling resistance tires.

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Got the front end together. Dave did an awesome job making the flip-up charge port doors. One on the right for J1772 and the one on the left will be for Chademo (Chademo not installed yet).

The Nissan badge comes from the '19 LEAF and it lights up when the truck is on and also when it is charging

Wired the LED driving lights to come on with the high beams:

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Welp ran into a snag. Right now it's not causing any issues but maybe will in the future. I noticed the last three cells #94, #95, and #96 are fluctuating quite a bit while charging or running the motor. I know those two BMS taps run really close to the HV main negative cable in the battery box. At idle they are perfectly balanced but the voltage spikes up and down with HV current. Really hoping I don't have to drop the battery but I may have no choice. I'm going to try some clamp on ferrite cores on the BMS wires where they go between boxes.

At idle:

While charging:

[Zieg]

Wow, that's interesting. Wonder if some copper shielding tape would also help?

Love the badge, nice that it works out being that it's all from the same brand!

[Jacobsmess]

Is this the same issue Janosch had with the 40kWh pack?

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Wow, that's interesting. Wonder if some copper shielding tape would also help?

Love the badge, nice that it works out being that it's all from the same brand!

I'm going to try the ferrites because it's quick and dirty, but if that doesn't work I'll drop the boxes and try to re-route the cell taps. Possibly use some shielded cable. Luckily it's pretty easy to get the boxes in and out. I know exactly where it was because I spent a lot of time mulling over the cable routing. I chose poorly.

I think the badge came out awesome too! Yeah it's cool it's all Nissan. Dave is going to try and reach out to Nissan and see if we can show it off somewhere. Imagine if you could buy a bare-bones EV truck like this new.

Is this the same issue Janosch had with the 40kWh pack?

I did some searching and it does indeed look like a similar issue. Though he was having half of the cells thrown out of whack and I'm only having 2-3 cells affected.

Here is the thread for others: viewtopic.php?p=49395#p49395

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Just a couple pics