I bought another Orion BMS 2 as i think it's an awesome BMS, alltough quite expensive.arber333 wrote: ↑Mon Apr 11, 2022 7:50 amMy favourite BMS right now is active balancers from Hankzor store https://www.aliexpress.com/item/1005002 ... 1802NyGfjMZapatero wrote: ↑Mon Apr 11, 2022 7:07 am Yesterday i took the battery apart. To get 96 of the 98 Kona-Cells in the Impreza it'll be the same puzzle as it was on the GT86 Project.
Also i have to convert 6 of the 8 10S3P Blocks to 9S3P. Two of the Blocks are by factory 9S3P (8x 10S3P + 2x 9S3P = 98 Cells). The Orion BMS can only support 96 Cells in my version, so i won't use 2 of them which equals in 1,3 Kwh less.
Subaru e-mpreza (Impreza) 96 - AWD with 2 Outlander rear motors
- Zapatero
- Posts: 443
- Joined: Fri Oct 25, 2019 11:08 am
- Location: Germany, Ulm
- Has thanked: 25 times
- Been thanked: 39 times
- Contact:
Re: Subaru Impreza 96 - AWD with 2 Outlander rear motors
- Zapatero
- Posts: 443
- Joined: Fri Oct 25, 2019 11:08 am
- Location: Germany, Ulm
- Has thanked: 25 times
- Been thanked: 39 times
- Contact:
Re: Subaru Impreza 96 - AWD with 2 Outlander rear motors
First important step: Cut the spare wheel well to make room for the battery box and the motor.
Fabricated some motor mounts:
then i've cut the rear differential mount to make room for the motor. Luckily it fitted between the screw mounts of the suspension links... BARELY!Fabricated some motor mounts:
- Zapatero
- Posts: 443
- Joined: Fri Oct 25, 2019 11:08 am
- Location: Germany, Ulm
- Has thanked: 25 times
- Been thanked: 39 times
- Contact:
Re: Subaru Impreza 96 - AWD with 2 Outlander rear motors
Finally hung the motor in the car, but unfortunately it's 4 cm too far down. So i took it out and cut the mounts off to attach them 4cm more up.
- Zapatero
- Posts: 443
- Joined: Fri Oct 25, 2019 11:08 am
- Location: Germany, Ulm
- Has thanked: 25 times
- Been thanked: 39 times
- Contact:
Re: Subaru Impreza 96 - AWD with 2 Outlander rear motors
Now the motor is in its final position in the car. It sits as low as the original exhaus manifold and therefore there shouldn't be any problems with the differential sticking out a little bit while driving. The now weakened subframe needs to be reinforced and then painted, but then the rear Motor is finally in the car. Next goal will be the front motor and then the suspension with the drive shafts.
- marcexec
- Posts: 122
- Joined: Tue May 14, 2019 12:52 pm
- Location: Dublin, Ireland
- Has thanked: 536 times
- Been thanked: 45 times
Re: Subaru Impreza 96 - AWD with 2 Outlander rear motors
Imprezzive there's no going back now.
Is it just the angle of the picture or could it be turned "backwards" (Neigung) around say the motor's axle to improve clearance/overall height?
Even it it means additional fabrication on the vertical face of the subframe to take the original mounts?
Is it just the angle of the picture or could it be turned "backwards" (Neigung) around say the motor's axle to improve clearance/overall height?
Even it it means additional fabrication on the vertical face of the subframe to take the original mounts?
A motorcyclist is never late, Frodo Baggins. Nor is he early. He arrives precisely when he means to.
Getting started guide for Celeron55's iPDM56
My Suzuki RF400 build @ES
Honda IMA & Lebowski howto
Getting started guide for Celeron55's iPDM56
My Suzuki RF400 build @ES
Honda IMA & Lebowski howto
- Zapatero
- Posts: 443
- Joined: Fri Oct 25, 2019 11:08 am
- Location: Germany, Ulm
- Has thanked: 25 times
- Been thanked: 39 times
- Contact:
Re: Subaru Impreza 96 - AWD with 2 Outlander rear motors
Imprezzivemarcexec wrote: ↑Wed Apr 13, 2022 3:52 pm Imprezzive there's no going back now.
Is it just the angle of the picture or could it be turned "backwards" (Neigung) around say the motor's axle to improve clearance/overall height?
Even it it means additional fabrication on the vertical face of the subframe to take the original mounts?
I'm not feeling very happy turning the engine in a position that it wasn't designed for as the gearbox filler screw and drain screw would be in weird positions. Also the room underneath the car seems to be like before
- Zapatero
- Posts: 443
- Joined: Fri Oct 25, 2019 11:08 am
- Location: Germany, Ulm
- Has thanked: 25 times
- Been thanked: 39 times
- Contact:
Re: Subaru Impreza 96 - AWD with 2 Outlander rear motors
I converted my brake pedal with the Prius brake pedal sensor, so regen can be adjusted properly. Setting regen properly just with the digital brake light switch is impossible in my opinion.
So i took the prius brake pedal apart and threw most if it away. I reused only the mount for the sensor and welded it to my brake pedal.
Also i welded a washer on the pedal that moves the sensor
So i took the prius brake pedal apart and threw most if it away. I reused only the mount for the sensor and welded it to my brake pedal.
Also i welded a washer on the pedal that moves the sensor
- Zapatero
- Posts: 443
- Joined: Fri Oct 25, 2019 11:08 am
- Location: Germany, Ulm
- Has thanked: 25 times
- Been thanked: 39 times
- Contact:
Re: Subaru Impreza 96 - AWD with 2 Outlander rear motors
I applied the Underbody coating
Next: I have to build the steeriung column with the Prius power steering motor and pot the axles back in the car and connect the wheels with the motor-
- Posts: 3265
- Joined: Mon Dec 24, 2018 1:37 pm
- Location: Slovenia
- Has thanked: 80 times
- Been thanked: 234 times
- Contact:
Re: Subaru Impreza 96 - AWD with 2 Outlander rear motors
Hardcore! I never thought of something like it . Truly variable brake regen!Zapatero wrote: ↑Tue Apr 26, 2022 7:21 am I converted my brake pedal with the Prius brake pedal sensor, so regen can be adjusted properly. Setting regen properly just with the digital brake light switch is impossible in my opinion.
So i took the prius brake pedal apart and threw most if it away. I reused only the mount for the sensor and welded it to my brake pedal.
Also i welded a washer on the pedal that moves the sensor
-
- Posts: 3265
- Joined: Mon Dec 24, 2018 1:37 pm
- Location: Slovenia
- Has thanked: 80 times
- Been thanked: 234 times
- Contact:
Re: Subaru Impreza 96 - AWD with 2 Outlander rear motors
- Zapatero
- Posts: 443
- Joined: Fri Oct 25, 2019 11:08 am
- Location: Germany, Ulm
- Has thanked: 25 times
- Been thanked: 39 times
- Contact:
Re: Subaru Impreza 96 - AWD with 2 Outlander rear motors
He also mounted the motor in the same position as it was original! Just checked the Page!arber333 wrote: ↑Tue Apr 26, 2022 7:44 amIt seems to have worked for a guy here...
https://twingorse.wordpress.com/
- EV_Builder
- Posts: 1199
- Joined: Tue Apr 28, 2020 3:50 pm
- Location: The Netherlands
- Has thanked: 16 times
- Been thanked: 33 times
- Contact:
Re: Subaru Impreza 96 - AWD with 2 Outlander rear motors
Very cool
I was planning doing this with the brake pressure msg on the CanBus from the ABS unit.
Converting an Porsche Panamera
see http://www.wdrautomatisering.nl for bespoke BMS modules.
see http://www.wdrautomatisering.nl for bespoke BMS modules.
- Zapatero
- Posts: 443
- Joined: Fri Oct 25, 2019 11:08 am
- Location: Germany, Ulm
- Has thanked: 25 times
- Been thanked: 39 times
- Contact:
Re: Subaru Impreza 96 - AWD with 2 Outlander rear motors
Cutting the driveshaft just feels so wrong!
Determining the final length of the outer driveshaft
Final length, now i need to have the adaptor milled
Rear motor is finally in!
- Zapatero
- Posts: 443
- Joined: Fri Oct 25, 2019 11:08 am
- Location: Germany, Ulm
- Has thanked: 25 times
- Been thanked: 39 times
- Contact:
Re: Subaru Impreza 96 - AWD with 2 Outlander rear motors
I cut an aluminum adaptor that i first shaped out of cardboard. This will protect the Charging Cable and make it accessible while working on it.
This part will be glued into the car, another part i will cut then that fits over this one as a cover. Glued into the car:
This part will be glued into the car, another part i will cut then that fits over this one as a cover. Glued into the car:
-
- Posts: 1801
- Joined: Sun Apr 03, 2022 1:57 pm
- Has thanked: 102 times
- Been thanked: 347 times
Re: Subaru Impreza 96 - AWD with 2 Outlander rear motors
Looking forward to seeing how this progresses!
I've had a H6 Legacy in the past, and driven the Impreza, and love the way they handle, the 4-wheel drive transforms the way they corner. An electric version with fully controllable front/back torque should be fantastic
I've had a H6 Legacy in the past, and driven the Impreza, and love the way they handle, the 4-wheel drive transforms the way they corner. An electric version with fully controllable front/back torque should be fantastic
-
- Posts: 1801
- Joined: Sun Apr 03, 2022 1:57 pm
- Has thanked: 102 times
- Been thanked: 347 times
Re: Subaru Impreza 96 - AWD with 2 Outlander rear motors
A question on the Outlander diff/motor if you don't mind. Mounting it the right way up as you have is the ideal but I wondered what you though about the possibility of rotating it 90degrees to bring the motor above the driveshaft? This might suit my install better as it moves the weight forward
I don't have a diff yet but from pictures it looks like the oil fill and drain plugs could be swapped to compensate for the rotation and keep the oil level at roughly the same height on the diff.
I don't have a diff yet but from pictures it looks like the oil fill and drain plugs could be swapped to compensate for the rotation and keep the oil level at roughly the same height on the diff.
- Zapatero
- Posts: 443
- Joined: Fri Oct 25, 2019 11:08 am
- Location: Germany, Ulm
- Has thanked: 25 times
- Been thanked: 39 times
- Contact:
Re: Subaru Impreza 96 - AWD with 2 Outlander rear motors
I really can't say if mounting it in another position than it was OEM will work, but i'm happy to share my experiences with the motor and the mounts.Pete9008 wrote: ↑Fri Apr 29, 2022 6:26 pm A question on the Outlander diff/motor if you don't mind. Mounting it the right way up as you have is the ideal but I wondered what you though about the possibility of rotating it 90degrees to bring the motor above the driveshaft? This might suit my install better as it moves the weight forward
I don't have a diff yet but from pictures it looks like the oil fill and drain plugs could be swapped to compensate for the rotation and keep the oil level at roughly the same height on the diff.
Mounts:
The upper mounts are only in vertical and lateral directions stable. They are not longitudinal stable, that mens forward and backwards they won't be able to absorb any mechanical forces. The one in lower front absorbs longitudinal forces and vertical forces. So if you would rotate the motor in ANY direction, you will definately have to fabricate custom mounts as the original ones will not be able to absorb the forces anymore. Even if you tilt it just like 10 degrees or so, it won't work! In Addition the rubbers in the mounts are very very soft! I expected them to be harder.
Water:
If you rotate the motor in another way then it was originally i would be concerned that there could build up pockets of air in the water flow and parts of the motor could overheat.
Oil
Drain and filler screw are definately different. Even if you rotate it by 90 Degrees, the Drain screw will be further up than the filler screw was before. Also you wouldn't be able to fully empty the oil out of the gearbox. Also i would be concerned that the oil can't be distrubuted as intended and therefore lead in damage.
Over all i would say: Try it out and let uns know if it works and my concerns are wrong The damage is a gearbox at max, so not too bad!
-
- Posts: 1801
- Joined: Sun Apr 03, 2022 1:57 pm
- Has thanked: 102 times
- Been thanked: 347 times
Re: Subaru Impreza 96 - AWD with 2 Outlander rear motors
Thanks for that. Shame on the fill and drain plus, from pictures it looked like it might work.
Good point on the mounts too, something that I hadn't considered (although I was expecting to need custom mounts for other reasons too).
Once I get a motor I'll have a look and see. The other option is to run it in reverse but that option makes me uneasy.
Good point on the mounts too, something that I hadn't considered (although I was expecting to need custom mounts for other reasons too).
Once I get a motor I'll have a look and see. The other option is to run it in reverse but that option makes me uneasy.
- aot93
- Posts: 198
- Joined: Mon Feb 15, 2021 5:45 pm
- Location: UK, West Sussex
- Has thanked: 6 times
- Been thanked: 43 times
Re: Subaru Impreza 96 - AWD with 2 Outlander rear motors
This going to be a very nice car.
For info my Outlander motor has been running upside-down for around 1,000 miles now with out problem.
Mounts I fabricated my own - The OEM rubber is very soft, not what you want in most conversions IMO
Water - I've had no problem with airlock, the water flows well and it does not get hot, but my car is quite light.
Oil - I fill through the drain, and drain through the fill, again seems fine, the oil thrower is basic and keeps the diff oiled. The service life on the oil is so long that I should not need to drain it before I have to take the motor out for something.
For info my Outlander motor has been running upside-down for around 1,000 miles now with out problem.
Mounts I fabricated my own - The OEM rubber is very soft, not what you want in most conversions IMO
Water - I've had no problem with airlock, the water flows well and it does not get hot, but my car is quite light.
Oil - I fill through the drain, and drain through the fill, again seems fine, the oil thrower is basic and keeps the diff oiled. The service life on the oil is so long that I should not need to drain it before I have to take the motor out for something.
-
- Posts: 1801
- Joined: Sun Apr 03, 2022 1:57 pm
- Has thanked: 102 times
- Been thanked: 347 times
Re: Subaru Impreza 96 - AWD with 2 Outlander rear motors
Sorry to go off topic but that is really interesting, do you have a build thread anywhere, any pictures? Do you actually have the motor down below the level of axle line then?
- Zapatero
- Posts: 443
- Joined: Fri Oct 25, 2019 11:08 am
- Location: Germany, Ulm
- Has thanked: 25 times
- Been thanked: 39 times
- Contact:
- Zapatero
- Posts: 443
- Joined: Fri Oct 25, 2019 11:08 am
- Location: Germany, Ulm
- Has thanked: 25 times
- Been thanked: 39 times
- Contact:
Re: Subaru Impreza 96 - AWD with 2 Outlander rear motors
The last few days i worked on the power steering conversion. I use a prius gen 2 power steering and i'm also going to integrate it properly in the canbus so i can adjust power steering support according to speed of the vehicle. The conversion was a lot of work in my opinion but it's the only proper way of doing it, as using the hydraulic power steering is not an option for me.
Most important for me was to keep the ability of the column to retract in case of a crash.
I've cut the impreza steering shaft on the upper part and connected that with the splined shaft of the prius power steering, but i had to have someone fabricate an adapter tube on a lathe: Next i've cut the the outside of the steering column and welded it to the prius motor, that i've cut, too. Also here i've had someone fabricate a proper adapter on a lathe. Then i aligned the steering motor under the dash to make sure there is enough room when using the tilting mechanism.
The product then was half a steering column with the motor: I cut a prius intermediate steering column shaft apart and welded the splined part directly on the outer hull of the sliding mechanism. Also i fabricated a base plate to screw on the lower half of the outer pipe:
Before: After: ^
The lower part of the inner shaft consists of a prius sliding inner mechanism and the Impreza lower end part that goes to the steering rack.
The outer hull consists of the Impreza parts that can retract in case of a crash and the inner part can too, due to the prius sliding mechanism. Tomorrow i will put it all in the car.
Most important for me was to keep the ability of the column to retract in case of a crash.
I've cut the impreza steering shaft on the upper part and connected that with the splined shaft of the prius power steering, but i had to have someone fabricate an adapter tube on a lathe: Next i've cut the the outside of the steering column and welded it to the prius motor, that i've cut, too. Also here i've had someone fabricate a proper adapter on a lathe. Then i aligned the steering motor under the dash to make sure there is enough room when using the tilting mechanism.
The product then was half a steering column with the motor: I cut a prius intermediate steering column shaft apart and welded the splined part directly on the outer hull of the sliding mechanism. Also i fabricated a base plate to screw on the lower half of the outer pipe:
Before: After: ^
The lower part of the inner shaft consists of a prius sliding inner mechanism and the Impreza lower end part that goes to the steering rack.
The outer hull consists of the Impreza parts that can retract in case of a crash and the inner part can too, due to the prius sliding mechanism. Tomorrow i will put it all in the car.
-
- Posts: 1801
- Joined: Sun Apr 03, 2022 1:57 pm
- Has thanked: 102 times
- Been thanked: 347 times
Re: Subaru Impreza 96 - AWD with 2 Outlander rear motors
Really enjoying the quality of the engineering and the attention to detail on this!
- aot93
- Posts: 198
- Joined: Mon Feb 15, 2021 5:45 pm
- Location: UK, West Sussex
- Has thanked: 6 times
- Been thanked: 43 times
Re: Subaru Impreza 96 - AWD with 2 Outlander rear motors
No the motor is still above / inline the axle but inverted from standard position.
Not quite up to your standard of engineering!
Not quite up to your standard of engineering!
- Bratitude
- Posts: 784
- Joined: Thu Jan 02, 2020 7:35 pm
- Location: Canada
- Has thanked: 57 times
- Been thanked: 176 times
- Contact:
Re: Subaru Impreza 96 - AWD with 2 Outlander rear motors
Was it just hard to source a electric Subaru steering rack?
They are like legos…
They are like legos…
https://bratindustries.net/ leaf motor couplers, adapter plates, custom drive train components