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Discussion Starter · #82 ·
122926


Mounting plate for the front of the Leaf motor. I will mount an aluminium Channel across this plate & take the motor (including torque) load at 2 rubber isolators.
 

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Discussion Starter · #84 ·
@Bratitude thanks for the post.

I had a very good look at your couplers. My issue was that I was using half the Leaf gearbox with a bearing. I also needed to make a spline anyway for the BMW gearbox side. Unfortunately, that meant that I needed a custom coupler - with the female splines on both ends.

I tried to find a plate BMW clutch but the way they were manufactured did not provide a mating face.
 

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@Bratitude thanks for the post.

I had a very good look at your couplers. My issue was that I was using half the Leaf gearbox with a bearing. I also needed to make a spline anyway for the BMW gearbox side. Unfortunately, that meant that I needed a custom coupler - with the female splines on both ends.

I tried to find a plate BMW clutch but the way they were manufactured did not provide a mating face.
if your salvaging the parts of the leaf gear box, why not the splines from that as well?

also, I don’t see an issue with the bmw clutch disks. Just machine the spline centure down, and do a interference fit into a bored out shaft. then tig weld.

plenty of bmw conversations done this way
 
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Discussion Starter · #86 ·
@Bratitude - some good points there. I could have taken that approach.

I don't the ability to do the work myself & was let down by a couple of machine shops. I think I took the path of least resistance (which was probably also the most expensive).

Next time!
 

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Discussion Starter · #88 ·
The motor is in place. Electronics almost there. Just need some brakes & should be able to do a test drive soon. I am waiting for new brake lines after I installed the iBooster and got rid of the vacuum booster.
123043
123044
 

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Discussion Starter · #92 ·
Update:

After getting everything running the next step was to secure the batteries.

In Australia there is a condition of registration that the batteries need to be restrained to cope with a 20G load in the case of a front-on crash.

After much consideration of options & desire not to rewire the BMS, I came up with the following solution:

  • Split the 24 cell pack in two & mount them vertically in the boot.
  • "Fold" the two 8 + 4 packs into a 6 high x 2 wide pack. The two packs are located behind the two front seats.
  • Use M8 threaded high tensile rod to hold down the packs.
  • Remove some bodywork to allow mounting of packs behind the seats.

The 12 cell packs are 50 kg each. This equals 10 kN force to be restrained. This can be achieved with 8 x M8 high tensile mounts/ treaded rods.

See:
123349
123350
 

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Discussion Starter · #93 ·
I am happy with the battery pack mounting.

The only issue is that after the battery change the system is now not starting.

It seems the precharge contactor is closing - but not the second one. I am getting no DTC's from the BMS - but I am getting one from the Motor/Inverter.

I am working with Isak at Resolve EV to do some troubleshooting.

See LeafSpy DTC:
123351


Any ideas?
 

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Discussion Starter · #94 ·
ps - my mechanical engineering skills are at my limit on this one. I think I need some specialist help.
 

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I have my Leaf Boat functioning, I suggest posting what if any changes have been made to the battery bms wiring.
( mr. obvious...sorry!) pay attention to grounding the bms case. and in my case...all the LEAF grounds must be good and together. this was a big help to me once I took care to join everything ( grounds) solidly
 

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Discussion Starter · #98 ·
I have my Leaf Boat functioning, I suggest posting what if any changes have been made to the battery bms wiring.
( mr. obvious...sorry!) pay attention to grounding the bms case. and in my case...all the LEAF grounds must be good and together. this was a big help to me once I took care to join everything ( grounds) solidly
Thanks @imwoody36 - I will check all the earthing. This could actually be the issue as the BMS is currently not bolted down and in the changes (re-arranging) I took out some earthing.

The good news is that LeafSpy is actually talking to the BMS and there are no errors there.

At Isak from Resolve's suggestion, I checked the pre-charge resistor and found it was no longer functioning. I have ordered and new one and it will arrive in the week of 30th August.
 

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Discussion Starter · #99 ·
My only change to the BMS wiring was to extend the wires by soldering a length in the middle. This was required when I split the 24 horizontal cell pack into two.

I was able to fold the other packs and make sure the BMS wiring was not changed (except for the HV connections).
 

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Discussion Starter · #100 ·
Update:

With the support of Isak @ Resolve I have resolved the issue.

Despite all my careful work (labelling etc) I made a major mistake in reversing the polarity of HV wires to the Motor/Invertor. I feel stupid admitting this but hopefully, it is a reminder to double and triple check.

The good news was that the pre-charge resistor acted as a fuse and no additional damage was done (at least that I am aware of).

There are now no DTC's and the motor spins. The voltages & resistance etc are as expected per Isak's video.

Everything took a while because the first (and second) precharge resistor had to come from the UK to Australia. I blew up two resistors before realising my mistake.

For reference, this is the replacement resistor I used. I could not get an OEM one from Japan. It was almost a swapin-swapout as they have the same dimensions but needed an extra lead termination.
https://au.element14.com/cgs-te-con...ton/res-33r-5-40w-radial-wirewound/dp/2805379

I now have a couple of resistors spare.
 
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