[brian_]

... How many cells are required? I've seen 48 cell packs and... something like 62 cell packs I think. Am I mistaken and they are all 48 cell?

All Leaf packs are 96S, meaning 96 groups of cells in series. Other than the 62 kWh pack, all Leaf packs consist of 48 modules each with 4 cells in a 2S2P configuration (two cells in a parallel group, two of those groups in series), so all of the modules are connected in series. Other than the earliest packs, the modules are stuck together in pairs (but still electrically separate), so there are 24 pairs of modules that are easiest to leave in pairs.

The 62 kWh pack has three different sizes of modules, still connected as 96S, but 96S3P (96 groups of 3 cells each, or 50% more cells of about the same size as the cells in the 40 kWh pack).

So there are no 48-cell or 62-cell Leaf packs. Other than the 62 kWh packs, they all have 48 modules.

 

[brian_]

You want the inverter intimate with the motor for a number of electrical engineering reasons. Putting it in the trunk, 10-12 feet away, is a bad idea.

I agree, but strangely some Toyota AWD hybrids apparently have the inverter for the rear motor located with the front inverter, in front. Still to be avoided, especially if you're splitting the battery into two packs so you can just put fewer where the inverter is going and more in the other location.

Charge controller remoting is fine.

The DC-to-DC converter can be anywhere, too... the high voltage cable for the relatively low power is small.

 

[brian_]

The stock LEAF 24/30kwh is 48 modules, 96 cells. Each module is 2 inseparable cells...

Each module is actually 4 cells, in a 2S2P configuration, but externally that doesn't matter so the rest of what followed that still applies. The 40 kWh battery has the same configuration.