I forgot to mention I've pulled enough scrap wire from the local industry recycle bins to wire this entire truck, including,
some 50mm^2
some 25mm^2
bunch of 6awg for the LV
J1772 male and female flying lead connectors including pilot dummy to talk with EVSE (I don't have an EVSE at home yet so time too make one
I've also collected an assortment of 14 12 and 10awg tew marine wire for more LV wiring and fuse/relay boxes to boot

 

Few more things to note,
I plan to daily this and as such a few more things,

Will be doing a proper HVAC of sorts for the cabin and battery heating and cooling. (I'd say the big thing here is battery heating for the coldish Vancouver winters.)
and later gonna do a pallet style forklift drop in DC genset to make a long range extender system, (I'm aware the internet is very divided on this but I'm gonna do it anyways, after all I would be doing this if it wasn't just for the "because I can".

Genset gonna happen only after the main build is done and driving. but that's the plan at least.

 

Parts Haul was a resounding success,
got the majority of the lv and lv components of a 2015 leaf, including all HV components and connectors, as well most all the LV harness parts,

Also got the stock leaf 96s BMS which will save me a fair bit off of buying the thunderstruck BMS
ive been told the schematics are available for the leaf which should help with the cell tap wiring, (only really one shot to get it right, I do have decent Smd rework equipment and skills if required)

Excited to have the
Power Steering
Power brake booster
ABS pump
AC compressor,
cabin heating/cooling element,

Should make this swap feel like a pretty modern creature comforts vehicle.

Since I've got essentially all the electric bits from a leaf (and saved a bunch of cash in the process) ill grab a resolve EV controller to and wiring harness to really ease of the work load in the wiring department

Also got
Motor mounts,
front subframe assembly with the bushings,
and dash subframe,
which will be awesome to save time fabricating new mounts for all these parts

Bunch of other goodies hiding here too, contactor box with pre-charge
battery heating pads,
relay boxes,
steering wheel
wheel speed sensors, and seems a lot more.

So as it seems today I got all the new brains, and shortly ill be getting the new Braun for this build.

Excited to get this Project kicked off.

 

Again one more thing, I read through the rules here as best I could but may have missed something, please let me know if I'm doing anything wrong or messing too much

 

MAN I wish we had Leafs in junkyards here. Never seen under the hood of one, and it really would have helped while wiring mine...

 

I think it was just right place right time, I asked if the guy had extra parts and he just gave me literally everything for a small extra fee, even gave me a 120v EVSE as I don't have one yet, ill make a 32a 240v one soon or buy the open evse kit.

 

Seems the Zombieverter comes in a heck of a lot cheaper then the resolve EV with the unsoldered version, im handy with a soldering iron, and some github programming work, would the Zombieverter be a no brainer here then?

 

Update, I wasn't able too get the motor out of the car in one peice so I split it up into its 4 components (I also have the front diff, so ill be able to make a coupler with that.

Ordered up a Zombieverter, might as well have some fun here, as i plan to add some other stuff later maybe CCS and such.

also I had salvaged a j1772 cable and so I've ordered up a openevse 50 Evse unit without the cable too save some money there, this way I can actually charge at a reasonable rate once I'm at that point.

Also was able to salvage a fairly long chunk and red and black 42mm2 cable seems it'll be usful here for somthing.

Still need to puck up that batteries, and continue on the hunt for a suitable minitruck.

 

Okay, Now reading into ZombieVerter, seeming to be missing some info, the Current shunt.
This IVT-S Shunt is pricey,

1. is this what im looking for, i understand the 1 and 2 can networks and 0,3 voltage readings, and im thinking +-1000a?
2. are the ebay listings for these in the 200$ range legit?
3. EVTV has them but not too far off of the digikey pricing.

Excited to continue things are happening

 

Eh 1000A is too big, remember measurement error is a percentage. Better to go with a 500A version IMO. I believe the ebay shunts have been discussed on the openinverter forums and I thought they said they were legit?

 

I’ve see some 300amp ivt shunts on leaf swaps, being the 80kw inverter.

EBay, you can find them for cheap

 

Thanks for the heads up,
I plan to upgrade the inverter and pack later on and thatll get me really close too the 300a, so i grabbed the 500A one, waiting on the connector set for the sensor yet

Also started tearing into the harnesses and labelling battery IGN and CAN signals in preparation of the ZombieVerter.
I split apart the PDM and Inverter harnesses here because I'm fairly sure i wont be able to fit the stack all together.

Been watching a lot of Cat videos it seems about Car parts and Inverter setup, trying to get up too speed and have as much of this prepared as possible.

Many more too go

 

Continuing on,

found relevant specs for the stock Leaf cooling pump and its in 2hz pwm to make it not spin at full speed.
Next up Contactor Block from the leaf.

seems the contractors are mounted in opposing directions and therefore polarity doesn't matter here as one or the other would have the correct magnet direction to blow it out,

on the other hand, the always hot side does matter as the precharge circuit wouldn't work otherwise, did some more digging and have labelled them as I've found.
dug a connector that matches the blocks LV connector, found the pin descriptions from the factory services manuals (once I found what I was actually looking for the naming is not clear lol)
bused the positives together as is described on the Zombieverter page and labelled the 3 negative coil pins.

Also Opened the Front gearbox/diff thing too harvest the coupling for the motor.

Next up find the BMS info in the Service manuals, if its there

EDIT, the BMS info is literally on the same page as the contactor info i found. Wiring continues

 

Note

no idea how long the Zombie takes to come, but the wait will be worth it, im super excited to get digging into the weeds of it

I'm sure this goes the same way for most, it just cant show up fast enough,
I've ordered the 3m harness and Enclosures from 2ali vendors as that's 2x the chance of it actually showing up, although as of late Aliexpress has been super solid for me

 

Gonna start from here dropping links too every online answer i find too all my questions, just in case anyone may find that useful
1. Zombie to Inverter and PDM
Zombie Reference

2. Leaf pump control and pinning information
tesla, same as nissan pinning/pwm
controlling via arduino

3. Leaf Contactor Block info
In the 2015 leaf EVB Service Manual page 27 it gives the Contactor coil pinout

4. BMS info
How to deppin
Connector-pins-wiring-canComms info

 

Okay so BMS pinning all figured out as of now, I have a "white bms" which requires the 4temp sensors and a temp sensor harness with only 3, so ill do the resistor change thing to make it work as is.

Next thing I want is the Leaf power steering,

I've seen 2 leads with info on it but nothing too actually using it,
just asking, no real info?

i thought ill just plug it in and see what happens
So I set it up on a stand, wired up the main power and the ignition to a 12v 35a meanwell supply (adjusted too 13.7v), powered it up, and it works!?!?!?

seems like many can devices this power steering unit falls back to some form of functional even with no CAN at all.

the pin descriptions for the Ignition and CAN came from the Service Manuals "stc" steering_control_system document.

 

I've since connected to the CANbus via SavvyCAN and can see some signal proportional too the force on the output.
I'm happy with it as is, but will have to take a log from a working car at some point to get the command frames required for it in order to have more control over its functionality

 

So the power steering just mounts to the column and the rack is essentially manual? Damn, that's pretty cool!

 

Yeah the leaf assist is fairly simple that's what pushed me to get it working.

 

I'd love to see more pictures. I went with the Resolve EV but I always wanted to build an EV kei truck.

Edit:
Also I have a lot of wiring diagrams for the Leaf 2013 and 2018 if you need.

I'm interested in seeing how you wire and adopt the leaf power steering.

 

I'd love to see more pictures. I went with the Resolve EV but I always wanted to build an EV kei truck.

There will be lots of pictures too come, for the time being I'm getting all the electrics pinning figured out and tested, I do not have a truck yet lol, all I know is I'll be getting one soon for this project, looking for a nicer example as my skills are in electrical and not body work.

I guess my project is a little backwards as most start with a vehicle that they plan to swap

 

Welcome! Excited to find another Kei fan!

I've been doing extensive research on converting a truck for a little over a year and just started the import process from Japan. I'm using a company called BeForward which has a large inventory but, as others have also experienced, they're a bit slow and lacking in communication. I'll be posting updates soon about the import process (on an ActyEV notes site I'm putting together) and I'm compiling resources to share!

Time for me to actually read your thread but let me know if you have any questions - I think we're both on a similar journey but I'm going AC50 for the motor instead of Leaf.

 

More updates,
I've got Batteries!

got 4x 10s3p modules of LG cells from a crashed Hyundia Kona EV and am currently having a blast designing a box and fastening system for them.

they will be rearranged into 4 modules of 24s1p to make the 96 for the leaf BMS

since I've got no truck yet its all just plans(with a lot of video and photo reference to guide me)
then again I love to mess around in cad and trying to make things parametric is a neat challenge for me.

here's my current design

I didn't get any others parts from either leaf of kona pack aside from the leaf BMS and the kona cells, so I've been looking for all the other required parts,
I found this amphenol service disconnect and fuse so far.

Not sure yet if I want a main battery connector or to use cable glands for the pack, not important yet though either

Zombieverters from JLC will be shipped soon, and enclosures are in aliexpress shipping land of who knows where.

Few next steps here, going to start tinking with the electric brake booster, i don't know enough about it yet to know if i can or cant use it, seems nobody has tried, but from ready the service manuals it looks as though the ABS pump is the more complex unit, and the booster is the more simple, I guess we will know soon (I do see 3 sets of CAN 😐)

 

Regarding the zombie-leaf wiring wiki page. Double check, it’s a work in progress. the drawing I made is right, but there is some differences in pins on the leaf throughout the years. any mistakes you find, feel free to update the wiki

 

I did notice a few deviations, the Inverter ignition pin seemed to not match the wiki (off by 1), I left it where it was and will see if it requires changing once I get too testing. thanks for the heads up.

 

So you're doing a closed battery box with no cell cooling at all?

 

Leaf never had any cooling either, ill be limiting my power usage, leaf did have heating plates, which I should be able to install below the cells yet.

 

So you're using Kona modules? I checked and unlike the Leaf, the Kona has a liquid cooling system. If so you should copy their cooling. I think there was a build recently that caught fire...

 

Been a Minute, Got a Kei today! 2002 carry 4x4

 

Very nice. You probably could mount the motor directly to the rear wheels without need for a differential. And so much room for batteries since it's raised.

 

Nah I'm bolting too the stock transmission, the gearing directly on the axles would be completely wrong.

 

Long time no chat,
I have not stopped work though,
Leaf motor is installed and truck runs on Electric power!

I made a driveline coupler using the inner spline of the Kei clutch and the existing leaf gearbox input shaft, rubber BMW driveshaft coupler was reccomended to me to take up any possible deviation on the shaft alignment, I 3dscanned the bellhousing and got the shaft alignment within 3thou.

Truck is being powered by magic in the photos.

 

Couldn't figure out how to get a video on here, so heres a link to it from google drive.
It Drives!