2012 Leaf Teardown and Tabletop Demo

[miscrms]

Thought some folks here might find this interesting

Part 1 I posted back in June:
[youtube]http://www.youtube.com/watch?v=8OBHiTLkANc[/youtube]

Part 2 finally posted last night!
[youtube]http://www.youtube.com/watch?v=ONOlbu2Haww[/youtube]

Eventually I will be transplanting most of this salvaged Leaf's drive and control systems into a 1973 Saab Sonnet III. With a stock weight of ~1800 lbs and a CdA lower than the original Honda Insight, should be pretty interesting if I can get it all working

Progress / Notes on Leaf System Re-use: http://www.diyelectriccar.com/forums/showthread.php/re-using-complete-leaf-drive-system-151458.html

Sonnet Build Thread: http://www.diyelectriccar.com/forums/showthread.php/new-ev-1973-saab-sonett-conversion-148730.html

Rob

 

[aarond12]

I've been watching the thread on DIY Electric Car for some time. I'm glad to see things are (wait for it...) on a roll!

That Saab is a beauty and should be amazing with the LEAF powertrain.

 

[finman100]

Nice videos! In case I missed it, are you also using the Leaf battery, or some other? good luck on the exciting project!

 

[DuncanCunningham]

I've watched those videos some time ago. I would love to do something like this to my VW bus and Bug but it will have to wait until our house remodel is done and I can figure out which way a screwdriver turns.

 

[miscrms]

Thanks all

finman, yes keeping the original battery. The donor spent most of its life in Maryland and Washington State, so seems to be in decent shape. 24k miles, showing 83% SOH and 11/12 bars. I am a little concerned about the effect the Phoenix heat has had on these '11/'12 batteries, but even if it degrades it should meet my needs for quite some time. My RT commute is only ~15 miles.

I'm also planning to install the batteries inside the vehicle, and considering running an AC duct back into the rear hatch where they will be installed. It will be interesting to see if that helps. I have covered parking at work, so hopefully they won't get baked too bad during the day. I may also try and rig up some cabin ventilation while parked if needed.

In general my approach is to use as much of the Leaf as practical, in order to keep the drive system working as close to original as possible. There are other folks out there working on talking directly to individual components, but this seemed like an approach that someone should try out and document.

Rob

 

[PatricioEV]

I've been wanting to do this for some time now. I did an old fashioned conversion of a Ford ZX2 a few years ago before the LEAF was available, and I've always wanted to take a complete LEAF and transfer it into something like a '64 Rambler Classic. Hell, even two complete LEAFs with common brake, accelerator signals into something like a Range Rover Evoque for some extra torque and fun! Great job and definitely keep this updated!

 

[miscrms]

Duncan just FYI these videos are both my own, and the second was just posted last night. There was a similar one out there for a "pegboard" demo of a 2013 drive system posted a while back. It didn't show much technical detail, but definitely helped build my confidence that it could be done Trying to do a better job of documenting the details so more folks might be able to do the same in the future.

I know of at least one other guy who has a similar project underway, with a 2015 drive system going into a 1985 Toyota Supra:
http://www.diyelectriccar.com/forums/showthread.php/85-supra-conversion-89391.html

Rob

 

[miscrms]

Just posted a third video. Similar table top demo, but now with closer to what I think are the minimal set of components required to operate without getting into spoofing. Also demonstrating charging, now that I sorted out my wiring issue.

[youtube]http://www.youtube.com/watch?v=bCOi19S71W4[/youtube]

Rob

 

[DuncanCunningham]

Duncan just FYI these videos are both my own, and the second was just posted last night. There was a similar one out there for a "pegboard" demo of a 2013 drive system posted a while back.

Yes, the pegboard one is the video I saw. sorry. glad it inspired you to do the same. We really do need a package that is as close to a production car performance for retro fitting older cars to EV's. I love my old VWs but my eyes do burn sometimes when Im tuning them in after any changes to the motors. i'd love to keep them as EVs.

 

[miscrms]

That's pretty much my thinking too. If it's riddles can be solved, it seems to me a wrecked (or potentially even just used) Leaf is a virtual treasure trove to a converter. Where else could you hope to find a 20kWh Li battery, BMS, 3kW charger, DC/DC converter, 80kW motor, inverter and reduction gear/transaxle already all integrated to work well together with all the needed controls for well under $10k? Never mind heat, AC, keyless entry, NAV, etc if you're interested!

There are certainly advantages to selecting your own components and designing your own controls, but I really hope this could open up a whole new era of possibilities for conversions with decent performance and polish on a very approachable budget!