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Discussion Starter · #41 ·
its been a while... but i made some progress!

van runs. im running it through my second vfd so i know i have 2 working units now.

looots still to do but here is a little video to catch you up so far.


shnitzel
 

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Very cool. I'm curious to see how the 7:1 rear gears work out. It's not an option for all RWD conversions, but some people have even put 9" Fords in MGBs, so...could save a bit of cost/complexity vs a TorqueBox or full transmission. I wonder what it's like at highway speeds, though a 50-year-old van may have different ideas as what counts as "highway speed"!

How'd you adapt the yoke to the Leaf motor?
 

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Discussion Starter · #43 ·
i actually have a 7.4 : 1 ratio gearset. the leaf was 8.2 : 1... so my top speed will be SLIGHTLY higher but not much. and my van is definitely lighter than the leaf. by a bunch......

the van has new shocks etc. should be good at highway speed. im not scared ;)

ive been driving it around without brakes for the last few days. ha ha ha ha.... very cool! it still has the 3 : 1 gear set in it and i cant believe how it pulls and climbs. the lower gears are going to be awesome!

i got the brakes hooked up last night. bleed them today. then just some van lights etc and ill insure it!

i bought the fiat clutch and used its center section. i had it machined down to be pressed into the driveshaft yoke. i welded it inside the yoke. i drilled and threaded a hole down the center of the nissan motor shaft. and i bolted it on there! seems good. before final assembly ill lock tight it in place to be sure it stays there.

hard to go to work when my van is so fun to play with! but i best go and put some hours in.... ha ha ha.

ill post a driving video as soon as i take one.

and as far as ground clearance. i measure 10" between the motor and the ground. my friends 2005 4x4 chev truck has 9.5" of ground clearance. so i should be good there ;)

hey "jbman".... your videos are gone!!!! what happened? i went to watch your putty video for reference again and it seems gone! too bad... your videos were a great help to my start....

shnitzel
 

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Discussion Starter · #46 ·
I just put a bit of time into the DC-DC converter. and sure enough it works too! applied power to the red and purple wires. voila! charging the 12v system!

now onto ordering a j1772 plug for the wall and learn to get the charger working!

closer and closer!

shnitzel
 

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Discussion Starter · #49 ·
I put the van back up on stands for some more updates. Going throught the gears etc.

My next big hurdle is the charger. i am hoping Dave will share his progress with me. I messaged him and am hoping for a response. maybe i can be his beta tester until he gets his car up and running.

heres another video of my progress. enjoy!

shnitzel

 

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Discussion Starter · #50 ·
Update::::: Van weighs 3080 lbs WITH ME IN IT!!!!!! sweeeet!
Im hoping someone that has made this charger work will take me in as a beta tester ;) someone???? im daring and excited to try! going to need a charger soon......

Im happy with the new wheels. They suit the look i think. Got a pack sniffer too!

shnitzel

 

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Discussion Starter · #51 ·
I got to drive an actual LEAF!!!! very fun! very peppy!!!! im getting more excited!!!

Almost got my brakes done. differential gears and charger last. then im done....... gotta figure this charger out. hopefully before im done. if so i cant decide whether the 3kw or 6kw.... might go cheap in hopes to still get the leaf one working someday.

heres another video update. hope you enjoy!

shnitzel

 

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Discussion Starter · #52 ·
Hello again,

I have my van running fully now. I bought the Resolve-Ev controller and installed it. a bit sad pulling the whole thunderstruck harness out, but ahh well..... anything worth doing once is worth doing 12 times???? ha ha ha.

so i have a fully driving, stopping, charging van!!!!!! sooo awesome! i drove it up to the factory today and plugged it in when i got home! soooo happy!

I think im the first econoline leaf in the world??? i dont know why that matters to me. but i think it is!!! ha ha ha. someones gotta be first ;)

lots of rattles to work out of it. and get the brakes adjusted a bit better. some shakes, some shimmys.... tidy the wiring with better switches. well get through it!

happy to have shared it with ya. i will post more when i do more. here is a little video of where its at now. filmed a little drive again.

hope you enjoy!

shnitzel

 

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Hello again,

I have my van running fully now. I bought the Resolve-Ev controller and installed it. a bit sad pulling the whole thunderstruck harness out, but ahh well..... anything worth doing once is worth doing 12 times???? ha ha ha.

so i have a fully driving, stopping, charging van!!!!!! sooo awesome! i drove it up to the factory today and plugged it in when i got home! soooo happy!

I think im the first econoline leaf in the world??? i dont know why that matters to me. but i think it is!!! ha ha ha. someones gotta be first ;)

lots of rattles to work out of it. and get the brakes adjusted a bit better. some shakes, some shimmys.... tidy the wiring with better switches. well get through it!

happy to have shared it with ya. i will post more when i do more. here is a little video of where its at now. filmed a little drive again.

hope you enjoy!

shnitzel

Very cool build. Love that you brought old iron back to life with new technology. Hoping to do a Leaf build myself -- thanks for being a the bleeding edge showing that these projects can be done.
 

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I love your shitty van :)

Congrats on getting it driveable!

That's the best milestone, when there's still wires jankily dangling all over, you're turning it on by hooking wires around, and yet it still drives. Magnificent :)
 

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Hello again,

I have my van running fully now. I bought the Resolve-Ev controller and installed it. a bit sad pulling the whole thunderstruck harness out, but ahh well..... anything worth doing once is worth doing 12 times???? ha ha ha.

so i have a fully driving, stopping, charging van!!!!!! sooo awesome! i drove it up to the factory today and plugged it in when i got home! soooo happy!

So why did you remove the Santa Rosa, California, USA controller and replace with a European Resolve-Ev controller?

shnitzel

 

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Discussion Starter · #57 ·
i switched just for the charger..,... it cost less to buy the resolve vcm than buying an aftermarket 6kw charger.

i will put the thunderstruck on a project that doesnt need an onboard charger. it will not go to waste.

i have over 500km on the van now. its working great!

its a tin can full of nails at over 42km/h. ha ha ha... so next is harley motor mounts and some sound dampening between the battery and floor. just waiting for the mounts to arrive. ill update after that on the vibrations.

i did check runout on my driveshaft. i see about .025" of runout. and i can make the retractable part of the driveshaft move about .020". so thats over .040" of runout. probably a lot for a driveshaft turning 7000rpm. i might adress this problem after the motor mounts are installed. one thing at a time.....

bit by bit ill work through it. this way i know for sure what matters and what doesnt.

still loving it! daily driver!!!! i even did a 60km trip for plywood last week. work van!!!

on another note, i bought a chrysler pacifica battery recently...... and i have the second whole leaf drivetrain with the thunderstruck vcm. snowmobile???? 4wd civic???? hmmmmm.... best just find the van rattles first ;)

shnitzel
 

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so next is harley motor mounts and some sound dampening between the battery and floor. just waiting for the mounts to arrive.
I don't get the harley motor mounts and the vibrating battery? The HV gloves are a nice touch. Have you considered just wearing them every time you you go for a drive-just in case. You got an interesting Mad Max build here, you might as well look the part!
 

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So inspiring to see someone just get on with it. About to start a very similar project to a very similar (if old British) van.

im excited by theResolve-Ev controller. Am I right that you are utilising the leaf bms and charger with this. Have you really managed to stick to just using the leaf kit without the huge bms and charger costs?

What sort of range you getting?
 
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