openinverter forum

Hello Together, I want to introduce you to my project here. I didn't start with the intention of building an electric car, but wanted to have a cool 1950s Ford Mercury. In Germany there are good and bad vintage cars. The good ones are original, cost little tax and insurance and are allowed to drive into emission zones. I want a bad one! With topchop, air springs, and good performance that scratches on the ground. Originally a 6.3L V8 with automatic was planned, now I switched to a Tesla LDU. A Tesla model 3 battery and PCS are also planned. Some Examples:

I like that car, and can imagine it rolling silently with electric power and kissing the tarmac onthe way.

THUMBS UP!

Very admirable project! Hope to have the LDU boards ready soon

johu wrote: ↑Thu Jun 18, 2020 7:52 pm Very admirable project! Hope to have the LDU boards ready soon

Hello Johannes,
I was already shopping. I have a LDU, a V4a board from Damien, a complete model 3 US battery, an additional EU PCS, an electric power steering system from a Opel corsa, a hella vacuum pump, water pumps and A/C compressor from a VW Hybrid.
The LDU is running at the moment on the workbench with 48V, some minor problems with the speed signal and temperature measurement. I hope our genius will find a solution for the PCS and the M3 BMS. I don't have the necessary LIN bus commands for the AC compressor. Maybe someone who has a father with an EV Golf could help and sniff Connectors, Pins an Baudrate are known.

That is simply stunning - love that sort of conversion!

So far I've made a drawing of the chassis and the battery box is almost done. And some pictures of my car (from the seller)

That battery box looks legit, want to see more of that as you get it filled up and wired.

a little update.
The chassis is almost done. The biggest challenge was getting very, very deep, creating enough space for the battery while preserving the trunk.
Next, the entire technology such as 12v battery, air compressor, heater, A / C compressor, cooler, charger, HV junkion box, vacuum pump is installed in the former engine compartment. This gives me a chassis that is ready to drive. The body is then put over it and fastened with a few bolts. The only connections are an electrical connector (no HV) and the steering.

Nice

What are the details on that rear suspension setup? Is that all custom?

It looks a lot simpler than the mess I've created.

The rear axle is a de dion axle made of a thick tube and mercedes IRS. Controlled by a triangulated four link. I think this is the easiest replacement for a solid axle to fit a tesla unit. I will use everything from Mercedes. Bearings, brake discs, calipers, parking brakes and drive shafts. Cheap and easy to get. And the best thing is that Zero EV sells matching drive shaft stubs for the Mercedes shafts.
https://zero-ev.co.uk/product/tesla-dri ... 64-993-vw/

muehlpower wrote: ↑Mon Aug 31, 2020 8:09 pm The rear axle is a de dion axle made of a thick tube and mercedes IRS. Controlled by a triangulated four link. I think this is the easiest replacement for a solid axle to fit a tesla unit. I will use everything from Mercedes. Bearings, brake discs, calipers, parking brakes and drive shafts. Cheap and easy to get. And the best thing is that Zero EV sells matching drive shaft stubs for the Mercedes shafts.
https://zero-ev.co.uk/product/tesla-dri ... 64-993-vw/

Nice!

I'm already neck deep in GTO parts, but I might need to try that for the next build. (of course I'm already planning the next build before the current one is finished)

A little update. I have built a frame that is in place of the old engine and carries everything you need except for the battery and motor. On top is a waterproof box with all controllers.
Of course everything is painted before it is finally assembled!

Amazing!! This is a real inspirational build for my '49 Pontiac fastback project that is waiting in the wings (after my current Tesla VW bus conversion project). I want it to be a low slung, stealth lead sled as well, but with a rough patina finish.

Did you design and build the whole new chassis from scratch to suit the Model 3 long batteries?

This looks really good. Beautifully designed and put together.

I've seen it today in real life. Very professional work indeed. And Christian is a very likeable guy. He gave me a lot of tips and hints for my upcoming VW T4 bus conversion. Sometimes a little to much input for my poor brain to process. Now I try write down as much as possible, and make a shopping list for my own project.
Thanks Chris. I'm looking fwd to meet you again someday.

Here is a little update. I have no idea how to sort or rotate the pictures . The motor is in its new home, the drive shafts are mounted. The battery box is piped and wired. I had to make a few special parts for the water pipes, otherwise the cover would not fit. The box also houses the main and pre-charge relays, as well as the main fuse. The current is measured by an ISA shunt. In addition, I installed the original model 3 shunt to make the original BMS happy. The fuse can be reached via an extra cover, as are the connections for the motor on the back and for the charger and accessories on the front of the box

Wow! Looking really impressive. Did you machine those custom parts?

It continues with the wiring. I put the two relays for DC fast charging in the Tesla GEN3 charger. This means I don't need an extra junction box. The first picture shows the volt sensing board that measures the voltage at the charge port for the BMW LIM. The fuses for the auxiliary power and the charger itself can also be seen.

bobby_come_lately wrote: ↑Wed Aug 04, 2021 6:10 am Wow! Looking really impressive. Did you machine those custom parts?

I made all the parts myself, fuse brakets, water connections, battery boxes, brakets for everything. Since I have a milling machine and a lathe, that's possible.

Really nice fit and execution !!

i have built a waterproof box that is housed in the engine compartment. It contains all the controllers that are necessary for driving and charging. There are 4 arduino DUE. One measures the spring height and the pressures in the air springs and controls the air compressor and the valves. One takes care of everything that has to do with heating and cooling, i.e. PTC cabin heater, battery heating, A/C compressor, fans, water pumps and bypass valves. One is for charging and controls the BMW LIM for fast charging and the Tesla generation 3 AC charger. No Damien hard or software for it! The last one filters the accelerator and brake pedal signals by measuring the speed on the front axle, comparing it with the drive unit speed and adjusting it if necessary to prevent the driven wheels from slipping. There is also a sound generator that simulates a V8 engine with a 4-speed automatic. And of course the BMW Lim and all the necessary fuses and relays

Absolutely incredible workmanship in every aspect. Wow!
Do you mind sharing a bit more details on how you’re controlling the relays with the arduinos? From what i can tell the output current from the board isn’t enough to directly control several larger relays at the same time since each relay requires about 100mA to hold closed. I’m looking at using relay shields or using arduino Motor shields to drive automotive relays.
Thanks in advance!

Hello Muehlpower,

Your build and the photos are a great inspiration for me, thanks so much.

Your deDion is very cool, my project has a parallel leaf spring rear end that I will be reusing so I’ll be building one similar, thanks again. Murphy

After the chassis with all electrical components was ready and everything had been tested and worked, I started to take care of the body. First, I cut out the bottom and made a new, flat one and fitted it in. A bit higher to fit the battery underneath.

Sie arbeitest sehr schnell! I'm impressed with how quickly you are moving through the phases. Also, how much quality of engineering you employ. Gut erledigt!