They're not. Not sure how they dealt with that. But mine frequently report that they're down towards zero in winter - too cold for charging.
Z3 EV Conversion
- Thread starter Andybpowell
- Start date
I haven't got much more done this week lots of staring at stuff and finalising decisions around the exact battery layout and mountings for the front battery box I've also finished drilling and tapping the base for the battery box.
To allow me to make the battery box mounts I've made a temporary mounting to hold it in place
Which is doing a fantastic job spot on
Hopefully I'll have a more productive day tomorrow
To allow me to make the battery box mounts I've made a temporary mounting to hold it in place
Which is doing a fantastic job spot on
Hopefully I'll have a more productive day tomorrow
Started the fabrication of the front battery box mountings this weekend my choice of steel was the same thing I used for the engine mounts
40mm x 20mm 2.5mm thick steel box section mainly because I've still got about 5m of it as with the engine mounts I've reinforced it where the mounting bolts go this time with steel tube welded in to stop it crushing when the bolts are tightened up
and here it is tacked in place
I couldn't go any further as I've run out of gas so probably won't get any more welding done until Tuesday so I went back to the charger
this is the bottom half of the top housing from the Nissan Leaf stack which originally housed the Leaf charger and DC to DC converter which I am not using for several reasons including the fact that it wouldn't fit under the bonnet but it will just using the lower half of the housing this conveniently gives me a safe place for the High Voltage connections to the motor and allows me to mount the charger I will be using
I have already milled part of the inside flat to allow good heat transfer from the charger
I then fitted a 6mm spacer plate so that the charger cleared other parts of the casting applied heat sink compound and bolted it in place the charger will be bolted directly to this plate
The reason for all of this is that the housing bolts directly on top of the inverter which is water cooled and I will have the coolant pump running during charging this should provide adequate cooling for the charger (I hope)
40mm x 20mm 2.5mm thick steel box section mainly because I've still got about 5m of it as with the engine mounts I've reinforced it where the mounting bolts go this time with steel tube welded in to stop it crushing when the bolts are tightened up
and here it is tacked in place
I couldn't go any further as I've run out of gas so probably won't get any more welding done until Tuesday so I went back to the charger
this is the bottom half of the top housing from the Nissan Leaf stack which originally housed the Leaf charger and DC to DC converter which I am not using for several reasons including the fact that it wouldn't fit under the bonnet but it will just using the lower half of the housing this conveniently gives me a safe place for the High Voltage connections to the motor and allows me to mount the charger I will be using
I have already milled part of the inside flat to allow good heat transfer from the charger
I then fitted a 6mm spacer plate so that the charger cleared other parts of the casting applied heat sink compound and bolted it in place the charger will be bolted directly to this plate
The reason for all of this is that the housing bolts directly on top of the inverter which is water cooled and I will have the coolant pump running during charging this should provide adequate cooling for the charger (I hope)
Last edited:
So it's been a little while without any updates mainly because of the weather it was just too hot and also too windy to weld outside. I did get some done the front mounting is finished though it cost me some burns that's the price of welding in a T shirt and I have made up the parts for the rear mounting just need to weld it all up
Also in other news all of the work I did to fit the Volvo(eltek) charger into the old leaf top housing was wasted as the charger literally blew up while I was charging the batteries and I can't seem to get another one for under £700 so I'm changing over to a Mitsubishi combined charger/dc to dc converter as they can be had for under £300. And here it is
I've tested the dc-dc part of it for charging the 12v battery which is all fine hope to get the HV battery charger tested tomorrow
I had to cut off the connector with all of the control wires as I couldn't get a plug for it at a reasonable price so I cut it off and extended all of the relevant cables to reach all of the way to the controller
It all looks a bit of a mess but it's not as dangerous as if looks I've even got the proper gloves for doing the HV connections
Also in other news all of the work I did to fit the Volvo(eltek) charger into the old leaf top housing was wasted as the charger literally blew up while I was charging the batteries and I can't seem to get another one for under £700 so I'm changing over to a Mitsubishi combined charger/dc to dc converter as they can be had for under £300. And here it is
I've tested the dc-dc part of it for charging the 12v battery which is all fine hope to get the HV battery charger tested tomorrow
I had to cut off the connector with all of the control wires as I couldn't get a plug for it at a reasonable price so I cut it off and extended all of the relevant cables to reach all of the way to the controller
It all looks a bit of a mess but it's not as dangerous as if looks I've even got the proper gloves for doing the HV connections
Last edited:
Too late for this but I have a bunch of connectors for the Outlander charger on the way from China!
Always the way
but to be honest I really just want to get on and get it on the road too many little things holding me up as you said sometimes you need to JFDI going to try to do the welding this afternoon
Same. Thought I'd be long done with this upgrade by now. But life/work keep getting in the way and it always takes longer than you think. Nearly done with the 12v wiring now. But that will all come out again at some point.
Just interested but what is the voltage of the HV
About 370 Volts depending on the state of charge
The ac part of the Mitsubishi charger is all tested and working, all of the front battery box mounts are finished,
The electric power steering pump brackets and mounting plate are done they just need cleaning up and painting and I even managed to use the existing pipework
also managed to make brackets for and fit the new ally radiator for cooling the motor, inverter and charger
It's getting there just slowly
The electric power steering pump brackets and mounting plate are done they just need cleaning up and painting and I even managed to use the existing pipework
also managed to make brackets for and fit the new ally radiator for cooling the motor, inverter and charger
It's getting there just slowly
Attachments
Last edited:
Looking great!
Thanks I'm not going to catch you up though not that it's a competition but it's motivational trying to catch up
We need to have an electric Z3 meet up!Thanks I'm not going to catch you up though not that it's a competition but it's motivational trying to catch up
Maybe with my next one...
Another minor update to be honest they all seem minor but take hours as @Tom Cheesewright has been finding out lately this is the power steering pump all fitted and plumbed in I managed to use all of the oem pipework and even got the cooler fitted in the original location
Last edited:
Impressive stuff.
Tony.
Tony.
Tested the power steering Saturday and guess what the pump's knackered trying not to be angry can't send it back I bought it months ago new one is on it's way on a positive note I did get to flush out the pipework and rack also got around to flushing all of the braking system through, refilling it and bleeding it and looking at what came out it needed doing it was very cloudy also got the location finalised for the charger
trying not to be angry can't send it back I bought it months ago new one is on it's way on a positive note I did get to flush out the pipework and rack also got around to flushing all of the braking system through, refilling it and bleeding it and looking at what came out it needed doing it was very cloudy also got the location finalised for the chargerAttachments
Last edited: