[windraver]

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.

 

[Ethan Eigenraam]

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

 

[ActyEV]

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.

 

[Ethan Eigenraam]

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 😐)

 

[Bratitude]

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

 

[remy_martian]

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

 

[Ethan Eigenraam]

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.

 

[Ethan Eigenraam]

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.

 

[windraver]

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.

Are you mixing modules from Leaf and Kona? Because with Leaf, it's a sealed metal box so arguably, the box is a heat sink lol.

But I would beware with other modules from other vehicles. While the Leaf module is consider weak in the industry power to weight, if you're using more effective modules, you're risking fire.

Also personally I wouldn't mix modules either.

 

[Ethan Eigenraam]

Are you mixing modules from Leaf and Kona? Because with Leaf, it's a sealed metal box so arguably, the box is a heat sink lol.

But I would beware with other modules from other vehicles. While the Leaf module is consider weak in the industry power to weight, if you're using more effective modules, you're risking fire.

Also personally I wouldn't mix modules either.

of course I'm not mixing modules they are all the same cells, and yes I'll be monitoring temperatures, the cells I have are a fair bit higher discharge then Stock leaf, and I will be using stock leaf power, I see no problems here, and of course I will monitor.

 

[windraver]

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...

 

[Ethan Eigenraam]

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

 

[windraver]

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.

 

[Ethan Eigenraam]

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.

 

[windraver]

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

Stock kei transmission or stock leaf transmission? The leaf transmission ratios are probably more efficient but the kei transmission might allow you to shift into gears for more power or speed but the extra weight and gear ratios might not be as efficient according to some.

 

[Ethan Eigenraam]

Stock kei transmission or stock leaf transmission? The leaf transmission ratios are probably more efficient but the kei transmission might allow you to shift into gears for more power or speed but the extra weight and gear ratios might not be as efficient according to some.

I'll have more clear info in coming updates

yes leaf bolting too kei tranny. to retain gear ratio options.

 

[Ethan Eigenraam]

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.

 

[Zieg]

Ahhhh yeah. Continuing to follow!

 

[Ethan Eigenraam]

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!

 

[CordinWit]

This is the Beginning of my First EV swap.

nothing is set in stone yet but Heres the going plan,

EM57 motor inverter charger stack,
Hyundai Kona battery Cells 96s1p, Or maybe 100s cause sounds cooler and squeeze a bit more wh,
Thunderstuck motors BMS, (was one for sale here but the guy backed out so ill buy new, (good to support those guys direct I've heard they do good work)
Suzuki Carry minitruck, Plan is to make an adapter from the EM57 to the truck tranny to learn the gear ratios, and maybe later go with a single reducer

Picking up the EM57 motor setup Today!
should also be getting the Kona power steering guts and power brake booster stuff, (getting the entire front subframe, so ill have the shaft to make a coupler for the truck as well.

Current Budget for this project is 10k and I should be able to hit that pretty close.

Will continue to update as I buy parts, And make another post to this thread later today with picks of the leaf parts haul if all goes too plan!

Welcome To the Family