[Finished] 1964 Rambler Classic 660 2dr sedan w/ GS450h

Tell us about the project you do with the open inverter
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PatrcioEV-ATX
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[Finished] 1964 Rambler Classic 660 2dr sedan w/ GS450h

Post by PatrcioEV-ATX »

Since I'm almost done with this project, figured I'd finally start a project thread in case I can inspire or be of assistance to anyone else.

Car:

1964 Rambler Classic 660 2dr sedan

Components:

2007 Lexus GS450h transmission and inverter
36kWh Tesla batteries from Mercedes B250e
Orion 2 BMS
EVBMW GS450h VCU
Stealth EV 6.6kw charger/DCDC combo
Hotstart fluid heater for cabin heat
Tesla Model S AC compressor for air conditioning

Everything about this car is new except the body and glass. Here is how it started:

Image

And this is where I am now:

Image

I just have a couple small cosmetic things to complete around the dash and center console and a couple of suspension issues to work out. Oh, and I broke the coupler locking MG1 and MG2 together, so that has to be redone! But I'm still driving around on just MG2.

There are lots and lost of photos and videos of my journey on my Instagram page. https://www.instagram.com/rambler_660e/

Hope you like it!
Attachments
660e 2.JPG
1998 Ford ZX2 - DC EV conversion(sold) http://evalbum.com/2093
2012 Nissan Leaf (sold)
2016 Mercedes B250e (sold)
2023 Volvo C40

Current: 1964 Rambler Classic 660 w/ GS450h set up. 36kwh Tesla batteries from B250e.
https://www.instagram.com/rambler_660e/
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Re: 1964 Rambler Classic 660 2dr sedan w/ GS450h

Post by PatrcioEV-ATX »

Personally, I'm all about the details.

Turn signal lights in OEM side view mirrors:

Image

Locator lights in door with period correct Rambler logo:

Image

Heated and cooled power leather seats, custom center console with black ash wood trim, ambient lighting in the OEM arm rests:

Image

And a very tidy motor compartment:

Image
1998 Ford ZX2 - DC EV conversion(sold) http://evalbum.com/2093
2012 Nissan Leaf (sold)
2016 Mercedes B250e (sold)
2023 Volvo C40

Current: 1964 Rambler Classic 660 w/ GS450h set up. 36kwh Tesla batteries from B250e.
https://www.instagram.com/rambler_660e/
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Re: 1964 Rambler Classic 660 2dr sedan w/ GS450h

Post by robertwa »

Beautiful build! Amazing attention to detail
Building: 1964 International Scout 80. LS600H transmission with zombieinverter, B250e battery pack
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Re: 1964 Rambler Classic 660 2dr sedan w/ GS450h

Post by nkiernan »

Amazing project, love this, love the details. Can't wait to hear more about how it runs for you
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Re: 1964 Rambler Classic 660 2dr sedan w/ GS450h

Post by PatrcioEV-ATX »

Car was a survivor but not much to look at. Only option from the factory was a 3spd auto transmission. Now it's loaded. I've added:

PS, PW, PB, 4 wheel discs, LSD rear, power leather heated and cooled front seats, Kenwood 10" stereo w/ 6 speakers, smart entry w/ push button start, electric parking brake, HUD... I'm using a cable driven shifter out of a Chevy to work the shift lever on the GS450h tranny so that I can use the parking pawl. Plus, cup holders!! A modern neccessity!

Image

Note the green Rambler "ready" light added to the original cluster. Comes on when a specific CAN message comes from the VCU. Also, I was able to use the cable driven "Weather Eye" climate control levers to move slide potentiometers for the climate control.

Image

Image
1998 Ford ZX2 - DC EV conversion(sold) http://evalbum.com/2093
2012 Nissan Leaf (sold)
2016 Mercedes B250e (sold)
2023 Volvo C40

Current: 1964 Rambler Classic 660 w/ GS450h set up. 36kwh Tesla batteries from B250e.
https://www.instagram.com/rambler_660e/
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Re: 1964 Rambler Classic 660 2dr sedan w/ GS450h

Post by alexbeatle »

Thank you for your post!
I have a question. I'm trying to find a compact fuse holder for 40A fuse for Tesla MS A/C compressor. What did you use?
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Re: 1964 Rambler Classic 660 2dr sedan w/ GS450h

Post by PatrcioEV-ATX »

alexbeatle wrote: Mon May 29, 2023 1:41 pm Thank you for your post!
I have a question. I'm trying to find a compact fuse holder for 40A fuse for Tesla MS A/C compressor. What did you use?
For heat, AC, DCDC, and charger, I use these inside my HVJB: https://www.evwest.com/catalog/product_ ... tidfvkp1i4

You can see them mounted to the right wall of the box: Image

For Trans Pump, PS (not yet implemented), PB, and a Constant line, I use this: Image
1998 Ford ZX2 - DC EV conversion(sold) http://evalbum.com/2093
2012 Nissan Leaf (sold)
2016 Mercedes B250e (sold)
2023 Volvo C40

Current: 1964 Rambler Classic 660 w/ GS450h set up. 36kwh Tesla batteries from B250e.
https://www.instagram.com/rambler_660e/
espriev
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Re: 1964 Rambler Classic 660 2dr sedan w/ GS450h

Post by espriev »

Any luck getting the Tesla AC compressor working?
I am hoping to find a turnkey solution for implementing a high voltage compressor with an existing AC system, seems possible.
All it has to do is take a cabin temperature input and cycle the compressor to achieve a desired temperature setting.
Under and over pressure protection can be handled with standard freon line pressure sensors.
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Re: 1964 Rambler Classic 660 2dr sedan w/ GS450h

Post by Proton »

Where did you buy the Gigavac disconnected from and it is 200Ah or 400Ah?
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Re: 1964 Rambler Classic 660 2dr sedan w/ GS450h

Post by PatrcioEV-ATX »

Proton wrote: Fri Aug 04, 2023 3:52 pm Where did you buy the Gigavac disconnected from and it is 200Ah or 400Ah?
https://www.evwest.com/catalog/index.ph ... c28e2eb2f6
1998 Ford ZX2 - DC EV conversion(sold) http://evalbum.com/2093
2012 Nissan Leaf (sold)
2016 Mercedes B250e (sold)
2023 Volvo C40

Current: 1964 Rambler Classic 660 w/ GS450h set up. 36kwh Tesla batteries from B250e.
https://www.instagram.com/rambler_660e/
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Re: 1964 Rambler Classic 660 2dr sedan w/ GS450h

Post by Proton »

If you have time can you explain your Electric Box? especially the automation in the box.
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Re: 1964 Rambler Classic 660 2dr sedan w/ GS450h

Post by PatrcioEV-ATX »

espriev wrote: Thu Aug 03, 2023 4:53 pm Any luck getting the Tesla AC compressor working?
I am hoping to find a turnkey solution for implementing a high voltage compressor with an existing AC system, seems possible.
All it has to do is take a cabin temperature input and cycle the compressor to achieve a desired temperature setting.
Under and over pressure protection can be handled with standard freon line pressure sensors.
Sorry, just noticed this question. Yes, the Tesla AC compressor works fine. It just needs a HV connection of course and a 12 volt accessory input and ground. Control is via a 12v pwm signal. I have an arduino mega that controls my HVAC system. I replaced what was in the car with a RestomodAir combo AC/Heat unit (Vapir 3), so it's essentially a "normal" AC setup where the compressor is electric rather than mechanical.

I can set the desired interior temp by a lever on my instrument cluster (cable driven original lever that moves a 0-5v slide potentiometer). That signal goes into my Mega and is mapped from 65-85 degrees. I have a temperature sensor in the cabin that tells the Mega the interior temp, so a small program to decide if I need heat or AC. For AC, I vary the PWM signal between 40-60% (I believe) based on fan speed (which I get from the RestomodAir potentiometer that controls it's fan).

The PWM signal for the Tesla compressor has to be in a certain frequency range, so I had to change that in the Arudino code. It then runs through an H bridge to bring it up to 12v. Also, my code won't allow heat or AC to come on unless the fan is on.

BUT! If all you want to do is replace a mechanical compressor with an electric one, you could use the regular ground from that system and get a simple PWM generator to provide a static signal for the Telsa unit. It wouldn't hurt anything to always have the PWM on (through acc power). The compressor would only work if it gets the ground from your system (and dryer).

see this thread in the DIYElectricCar forum: https://www.diyelectriccar.com/threads/ ... 978/page-2
1998 Ford ZX2 - DC EV conversion(sold) http://evalbum.com/2093
2012 Nissan Leaf (sold)
2016 Mercedes B250e (sold)
2023 Volvo C40

Current: 1964 Rambler Classic 660 w/ GS450h set up. 36kwh Tesla batteries from B250e.
https://www.instagram.com/rambler_660e/
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Re: 1964 Rambler Classic 660 2dr sedan w/ GS450h

Post by PatrcioEV-ATX »

Proton wrote: Sun Aug 06, 2023 5:29 pm If you have time can you explain your Electric Box? especially the automation in the box.
The HVJB box consists of positive and negative contactors, a pre-charge relay and resister, a contactor for my heater, fuses (for the charger, DCDC converter, AC compressor, and heater), the Isabellenhütte shunt, an Arduino Nano, a CAN bus module, a 5v triggered 4 relay module, a 12v to 5v buck converter, the main shut off switch, and a couple of power distribution blocks.

12 volt power going into the box is through a relay that gets ground from my Orion BMS. If the BMS says everything is ok, then power goes to the box. I've simplified the HV contactor sequence so that it's just driven on getting power to the Arduino. The Arduino then runs that sequence to turn on/off the relays which close/open the contactors. I also have LED lights on the lid of the box that light up indicating when each contactor is closed.

There are two CAN networks; one from the shunt to the GS450h VCU and one that goes between my VCU, the Nano and a Mega in my center console. The shunt CAN network just sends shunt info to the VCU. The other CAN network sends quite a bit of information around including a message to turn the heater on/off, which closes/opens the heater contactor. That message comes from the Mega based on cabin temperature vs desired temp (and if climate is turned on and fan is blowing). The Nano also monitors the temp of the fluid in the heater to keep it between 140-160 degrees.

That's all I can think of off the top of my head, but please let me know if you would like any further detail.
1998 Ford ZX2 - DC EV conversion(sold) http://evalbum.com/2093
2012 Nissan Leaf (sold)
2016 Mercedes B250e (sold)
2023 Volvo C40

Current: 1964 Rambler Classic 660 w/ GS450h set up. 36kwh Tesla batteries from B250e.
https://www.instagram.com/rambler_660e/
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Re: 1964 Rambler Classic 660 2dr sedan w/ GS450h

Post by PatrcioEV-ATX »

deleted
1998 Ford ZX2 - DC EV conversion(sold) http://evalbum.com/2093
2012 Nissan Leaf (sold)
2016 Mercedes B250e (sold)
2023 Volvo C40

Current: 1964 Rambler Classic 660 w/ GS450h set up. 36kwh Tesla batteries from B250e.
https://www.instagram.com/rambler_660e/
espriev
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Re: 1964 Rambler Classic 660 2dr sedan w/ GS450h

Post by espriev »

Thanks for the informative reply!
Does the frequency of the PWM signal act as a "temperature" control, and by changing the frequency on can set the compressor on-off cycle thereby controlling the AC temp?
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Re: 1964 Rambler Classic 660 2dr sedan w/ GS450h

Post by PatrcioEV-ATX »

espriev wrote: Tue Aug 08, 2023 1:00 pm Thanks for the informative reply!
Does the frequency of the PWM signal act as a "temperature" control, and by changing the frequency on can set the compressor on-off cycle thereby controlling the AC temp?
No. It just only recognizes a PWM sent within a certain frequency (in that DIY thread I linked). The PWM is what controls the speed of the compressor. I don't know enough about AC systems to know if the speed of the compressor can change the temp of the coolant, but I doubt it. I think it only impacts how quickly it cools down.
1998 Ford ZX2 - DC EV conversion(sold) http://evalbum.com/2093
2012 Nissan Leaf (sold)
2016 Mercedes B250e (sold)
2023 Volvo C40

Current: 1964 Rambler Classic 660 w/ GS450h set up. 36kwh Tesla batteries from B250e.
https://www.instagram.com/rambler_660e/
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Re: 1964 Rambler Classic 660 2dr sedan w/ GS450h [DRIVING]

Post by PatrcioEV-ATX »

Finally decided to take it to a professional fabricator. There was a bit of a clunk in the rear end I installed whenever I let off the accelerator. Hopefully, this will get fixed once and for all! Also, he had scales and weighed the car. I added much more weight than I thought - around 900lbs! Plus side, it's now very well balanced front to back.

Image
Image
Image
1998 Ford ZX2 - DC EV conversion(sold) http://evalbum.com/2093
2012 Nissan Leaf (sold)
2016 Mercedes B250e (sold)
2023 Volvo C40

Current: 1964 Rambler Classic 660 w/ GS450h set up. 36kwh Tesla batteries from B250e.
https://www.instagram.com/rambler_660e/
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Re: 1964 Rambler Classic 660 2dr sedan w/ GS450h [DRIVING]

Post by PatrcioEV-ATX »

Thought I'd share a walkthrough of the motor compartment and the custom Nextion display I have in the center console:



1998 Ford ZX2 - DC EV conversion(sold) http://evalbum.com/2093
2012 Nissan Leaf (sold)
2016 Mercedes B250e (sold)
2023 Volvo C40

Current: 1964 Rambler Classic 660 w/ GS450h set up. 36kwh Tesla batteries from B250e.
https://www.instagram.com/rambler_660e/
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Re: [DRIVING] 1964 Rambler Classic 660 2dr sedan w/ GS450h

Post by Bigpie »

Very tidy. Nice work
VW Beetle 2003
Outlander front generator
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Re: 1964 Rambler Classic 660 2dr sedan w/ GS450h [DRIVING]

Post by Proton »

PatrcioEV-ATX wrote: Wed Aug 16, 2023 2:07 pm Thought I'd share a walkthrough of the motor compartment and the custom Nextion display I have in the center console:
........
Trying to learn some Arduino right now. Would you be able to make a video to see what parts and code is involved in making all the data to show up on that screen?
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Re: 1964 Rambler Classic 660 2dr sedan w/ GS450h [DRIVING]

Post by PatrcioEV-ATX »

Proton wrote: Mon Aug 21, 2023 6:08 pm Trying to learn some Arduino right now. Would you be able to make a video to see what parts and code is involved in making all the data to show up on that screen?

Check out videos on my Instagram page rambler_660e for other views of the devices. I can't film those now without removing my center console (bit of a design flaw).

Main parts: GS450h VCU, MCP2515 CANBUS module, Arduino Mega, Nextion 3.5" touch screen.

If wanting to use CAN, you'll need to learn the basics of sending and receiving that protocol. Nextion has it's own commands you'll need to write into whatever you're using to send it info, also you'll need to learn the basics of programming the Nextion. It has its own code loaded to the display. And... if you want to do anything looking like what I did, you'll need to know how to do graphic design. Most of the graphics you see in my screens are pictures loaded to the Nextion.

I am using one of the VCU's CAN lines to connect to the MCP2515 which is connected to the Mega. The Nextion is also connected to the Mega. There is code in my VCU that sends CAN messages out and reads messages coming in from the Arduino. For the MPH value for example, code in my VCU calculates my MPH based on MG2 speed and other factors (rear differential ratio, tire rotations per mile, etc) and sends that value over CAN to the Mega (through the MCP2515). The Mega then sends that value to the Nextion over a serial connection.

For things like Valet mode, the Nextion has dual state buttons programmed into it. When I press the Valet button on the display, it sends that information to the Mega (on/off). The Mega reads the value and sends it to the VCU over CAN. Code in the VCU then adjusts the max commanded torque based on whether or not Valet Mode is true (on).

For things like adjusting the set temperature of the HVAC system, I have a lever on my instrument cluster that moves a cable which moves a 5volt slide potentiometer. That pot sends 0-5v to a Mega analog read pin. The mega maps 0-5v to 65-75 numeric value that it sends to the display. The Mega also has code to turn on the heater or AC compressor depending on the relationship of the set temp to the cabin temp. There are a LOT of other inputs and outputs which is why I am using a Mega to control so many things. The VCU simply doesn't have enough I/O pins for my build. I have a LOT of stuff being controlled by the Mega. I also have a lot of "fun" info in my display. For instance, when I apply the brakes (or the VCU turns on the brake lights during heavy regen) the brake lights light up on my flow screen. Not needed, but definitely fun.

If you only want to display data (and maybe have a small amount of info going back and forth), @Gregski has proven that if you don't plan on using the WiFi module in the 450h VCU, you can attach a Nextion to the serial pins on the WiFi header on the VCU. That bypasses the MCP2515 module and the Mega, but limits what you can do with the display. And again, if you only want to display info from the VCU, you don't need a touchscreen. Nextion makes the same screen that is non-touch. Frankly you could use just about any serial connected screen, but the Nextion software makes creating text and number boxes very easy.
1998 Ford ZX2 - DC EV conversion(sold) http://evalbum.com/2093
2012 Nissan Leaf (sold)
2016 Mercedes B250e (sold)
2023 Volvo C40

Current: 1964 Rambler Classic 660 w/ GS450h set up. 36kwh Tesla batteries from B250e.
https://www.instagram.com/rambler_660e/
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Re: 1964 Rambler Classic 660 2dr sedan w/ GS450h [DRIVING]

Post by PatrcioEV-ATX »

Proton wrote: Mon Aug 21, 2023 6:08 pm Trying to learn some Arduino right now. Would you be able to make a video to see what parts and code is involved in making all the data to show up on that screen?
also, check this out: viewtopic.php?t=4078

lots of good info on using the serial connections on the 450h VCU and the Nextion display.
1998 Ford ZX2 - DC EV conversion(sold) http://evalbum.com/2093
2012 Nissan Leaf (sold)
2016 Mercedes B250e (sold)
2023 Volvo C40

Current: 1964 Rambler Classic 660 w/ GS450h set up. 36kwh Tesla batteries from B250e.
https://www.instagram.com/rambler_660e/
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Re: [DRIVING] 1964 Rambler Classic 660 2dr sedan w/ GS450h

Post by Proton »

Thank you Patricio for all info.

I got yesterday a lot of stuff. hopefully the big screen I ordered works. I think I got right most of the parts I ordered.
Arduino-CAN.jpg
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Re: [DRIVING] 1964 Rambler Classic 660 2dr sedan w/ GS450h

Post by PatrcioEV-ATX »

Proton wrote: Tue Aug 22, 2023 2:29 pm Thank you Patricio for all info.

I got yesterday a lot of stuff. hopefully the big screen I ordered works. I think I got right most of the parts I ordered.
Arduino-CAN.jpg
Looks good. I have a Nano as well in my HVJB that controls all the contactors, including the contactor to turn on/off my heater (Hotstart block heater). It reads a Heat value (on/off) over CAN and the temperature of the coolant in the system to know what to do with the heater. What are you using the small screen for?
1998 Ford ZX2 - DC EV conversion(sold) http://evalbum.com/2093
2012 Nissan Leaf (sold)
2016 Mercedes B250e (sold)
2023 Volvo C40

Current: 1964 Rambler Classic 660 w/ GS450h set up. 36kwh Tesla batteries from B250e.
https://www.instagram.com/rambler_660e/
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Re: [DRIVING] 1964 Rambler Classic 660 2dr sedan w/ GS450h

Post by Proton »

The small screens are just for testing and for my kids to learn too. If I can use them in the car for something, I will use them.
I am also trying to use them with my CO2 sensor in the house. For the last 10 years I always have a window open in the house just to keep the CO2 under 800 ppm. I have to manually adjust the opening depending on the season and temperature outside.
I want to automate a fan to pull fresh air in the housed based on the CO2 sensor reading.


I found a cool video for CO2 sensor and I can use the small screen.

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