1993 FD Rx7 with Tesla LDU and ElectricGT Batteries

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rjmcdermott81
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Re: 1993 FD Rx7

Post by rjmcdermott81 »

I mounted and wired in an engine start button from a Honda s2000 to send the start signal. I'm sure I overpayed by using one from an s2000 but I have nostalgia because it was my first real sports car.

This mounted in the cigarette lighter hole really easily. I just had to dremel out a few grooves so it would slide in. Wiring was easy as well, I used the existing pos/neg from the cigarette lighter since it is already switched power. Then when pressed it sends 12v out.
engine start button.jpg
rjmcdermott81
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Re: 1993 FD Rx7

Post by rjmcdermott81 »

19mm coolant adapter from zeroev mounted on the drive unit. Nicely machined part.
coolant adapter.jpg
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Re: 1993 FD Rx7

Post by rjmcdermott81 »

Waterpump mount done and wired in.
waterpump pic 3.jpg
waterpump pic 1.jpg
waterpump pic 2.jpg
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Re: 1993 FD Rx7

Post by Zapatero »

I'm already in love with this RX7!
As a big fan of japanese cars i think one does see them way to rarely to be considered for electric conversions!

I love driving my Toyota GT86 EV - it's absolutely awesome (project threat is on here, too). I'm sure you will have the same fun with your RX7!
Also it's great how you involve your Kids :)
rjmcdermott81
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Re: 1993 FD Rx7

Post by rjmcdermott81 »

Zapatero wrote: Wed Feb 03, 2021 7:58 pm I'm already in love with this RX7!
As a big fan of japanese cars i think one does see them way to rarely to be considered for electric conversions!

I love driving my Toyota GT86 EV - it's absolutely awesome (project threat is on here, too). I'm sure you will have the same fun with your RX7!
Also it's great how you involve your Kids :)
Thanks! I've gone through your entire build and it's helped me a bunch along the way. Love the GT86.
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Re: 1993 FD Rx7 with Tesla LDU and ElectricGT Batteries

Post by rjmcdermott81 »

J1772 connector is mounted (the label is upside down because I had to swap the door to the other side...I'll cover this up later). It was much easier than I expected. I just needed to alter the angle so the charging connector wouldn't hit the body.
charger holder-1.jpg
charger holder-2.jpg
charger holder-1charger holder-3.jpg
charger holder-4.jpg
One more thing down...
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Re: 1993 FD Rx7 with Tesla LDU and ElectricGT Batteries

Post by rjmcdermott81 »

Another small update, working on the details. I created a design to hold the 2/00 high voltage wires. I'll adapt the design based on placement after I get the batteries.
HV cable holder-5.jpg
HV cable holder-2.jpg
HV cable holder-4.jpg
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Re: 1993 FD Rx7

Post by FJ3422 »

Good work ! Nice 3D printing work !
rjmcdermott81 wrote: Wed Feb 03, 2021 3:30 am waterpump pic 1.jpg
Do you use this Bosch PAD-12V pump for just a partial coolant circuit, or for the complete (inverter-motor-charger-batteries) coolant loop ?
Where the Bosch PAD's can create a differential pressure of around 0,1-0,15bar (at around 1 Amp), the usual 'Tesla'-pumps are spec'd around 0,5-0,7bar (at around 7 Amps). When you have a large / complex loop with a high flow resistance, you might have to consider a more powerful pump.
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Re: 1993 FD Rx7

Post by rjmcdermott81 »

FJ3422 wrote: Tue Feb 16, 2021 4:25 pm Good work ! Nice 3D printing work !
rjmcdermott81 wrote: Wed Feb 03, 2021 3:30 am waterpump pic 1.jpg
Do you use this Bosch PAD-12V pump for just a partial coolant circuit, or for the complete (inverter-motor-charger-batteries) coolant loop ?
Where the Bosch PAD's can create a differential pressure of around 0,1-0,15bar (at around 1 Amp), the usual 'Tesla'-pumps are spec'd around 0,5-0,7bar (at around 7 Amps). When you have a large / complex loop with a high flow resistance, you might have to consider a more powerful pump.
You are 100% right. I looked over at Boxster EV's build thread and he is using a Davies Craig pump so I just ordered one. Much much higher flow rate.
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Re: 1993 FD Rx7

Post by muehlpower »

rjmcdermott81 wrote: Mon Feb 22, 2021 3:37 am
FJ3422 wrote: Tue Feb 16, 2021 4:25 pm Good work ! Nice 3D printing work !
rjmcdermott81 wrote: Wed Feb 03, 2021 3:30 am waterpump pic 1.jpg
Do you use this Bosch PAD-12V pump for just a partial coolant circuit, or for the complete (inverter-motor-charger-batteries) coolant loop ?
Where the Bosch PAD's can create a differential pressure of around 0,1-0,15bar (at around 1 Amp), the usual 'Tesla'-pumps are spec'd around 0,5-0,7bar (at around 7 Amps). When you have a large / complex loop with a high flow resistance, you might have to consider a more powerful pump.
You are 100% right. I looked over at Boxster EV's build thread and he is using a Davies Craig pump so I just ordered one. Much much higher flow rate.
I use Bosch PCE pumps. They have more power and can be controlled via PWM. Without PWM they run at 100%. A dry run protection is also integrated.
They are easy to get because they are used in many VW models, but the VW version has a different plug and pin assignment.
I paid € 30.- each
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Bosch PCE.pdf
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rjmcdermott81
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Re: 1993 FD Rx7 with Tesla LDU and ElectricGT Batteries

Post by rjmcdermott81 »

Progress update. I took a break but getting back in it now.

Starting to work on the high-voltage box and mounts for each part - resistors, contactors, etc. These are not the final wires...just for testing.
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rjmcdermott81
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Re: 1993 FD Rx7 with Tesla LDU and ElectricGT Batteries

Post by rjmcdermott81 »

Taking a break to do the axles and wheel-bearings on the e30
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Re: 1993 FD Rx7 with Tesla LDU and ElectricGT Batteries

Post by rjmcdermott81 »

Batteries are here!! (2 more on the way but this is what I need to start building the box)
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Re: 1993 FD Rx7 with Tesla LDU and ElectricGT Batteries

Post by rjmcdermott81 »

Arranging the batteries in the way they will fit in the car.
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Re: 1993 FD Rx7 with Tesla LDU and ElectricGT Batteries

Post by rjmcdermott81 »

Working on a battery holder template and then getting it back from Sendcutsend.com. So easy and such nice delivery.
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Re: 1993 FD Rx7 with Tesla LDU and ElectricGT Batteries

Post by rjmcdermott81 »

Now that I have the first one dialed in, ordering the holder plates for all the batteries
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Re: 1993 FD Rx7 with Tesla LDU and ElectricGT Batteries

Post by Boxster EV »

Loving this build. Thanks for sharing such a comprehensive write-up.

You might want to mount the pre-charge resistors on a metal plate. They will get warm and could melt the plastic.
Porsche 986 powered by a Tesla large drive unit. Backwards. Build documented here and Instagram @tesla_porsche here.
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Re: 1993 FD Rx7 with Tesla LDU and ElectricGT Batteries

Post by rjmcdermott81 »

Boxster EV wrote: Fri Apr 23, 2021 1:12 pm Loving this build. Thanks for sharing such a comprehensive write-up.

You might want to mount the pre-charge resistors on a metal plate. They will get warm and could melt the plastic.
Thanks - I appreciate feedback like this. I think now that I have the file and design dialed in I will send it out to have it 3d printed in metal. Good excuse to try that for the first time.
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Re: 1993 FD Rx7 with Tesla LDU and ElectricGT Batteries

Post by rjmcdermott81 »

Battery mounts and steel square tube are in to make the battery box. I plan to build it one battery section at a time test fitting in the vehicle to squeeze it all in.
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These brackets will hold the chill plates on the single batteries
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Here is a section of three batteries with chill plates sandwiched in between
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Here it is with the square tube on the side. I will cut, drill and then mount to this.
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Also, at Walmart I saw the new Mustang E parked at the charger. I've been totally excited after reading about it in magazines but seeing this one...man I hope they don't all look like this. It's probably the ugly wheels or something but it did not look good.
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Re: 1993 FD Rx7 with Tesla LDU and ElectricGT Batteries

Post by celeron55 »

The Mustang Mach E looks weird in my opinion too, but I hear they put some nice tech into it. Now, let's just hope someone safely crashes one and puts the parts up on Ebay...
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Re: 1993 FD Rx7 with Tesla LDU and ElectricGT Batteries

Post by rjmcdermott81 »

My neighbor caught me working on the battery base the other day...
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Re: 1993 FD Rx7 with Tesla LDU and ElectricGT Batteries

Post by rjmcdermott81 »

k, progress on the battery mount has been slow. The first design had the batteries sitting too high so now I have a steel base that will mount directly to the subframe.

Base on subframe
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Batteries mounted to base (this is upside down)
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Base in car
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Testing with batteries
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Now with bracket on top batteries
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Test fitting other 6 batteries
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Clearance under the hood
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Attachments
IMG_8422.jpeg
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Re: 1993 FD Rx7 with Tesla LDU and ElectricGT Batteries

Post by johu »

rjmcdermott81 wrote: Thu May 13, 2021 11:07 am My neighbor caught me working on the battery base the other day...
Thats what is great about working outside :)
Nice work.
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Re: 1993 FD Rx7 with Tesla LDU and ElectricGT Batteries

Post by rjmcdermott81 »

Boxed out the lower section of the battery box.
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