[Steel]

Hello, short video of my conversion : https://youtu.be/fs7krsKv70M

The suspension is from a Corvette C5. Coilovers from GAZ.

Tesla engine cracked by Michal Elias from Advantics and motor is to be controlled by their VCU.
Bought BMS controller from EVTV to check battery modules.
Logic board from Damien Maguire to control the gen 2 charger.

I`m more used to the welder and grinder but learning more and more electronics.

BR Pär Stål from snowy Sweden.

 

[Yabert]

Awesome! This sleeper car will surprised ton of person during an acceleration

 

[brian_]

Very nice job! The battery is well-integrated into the van body. Of course there's no Vito powertrain or chassis left.

For people in North America, this vehicle was not sold here, but it is an earlier generation of the van now offered here as the Metris. It looks like the W639 generation, which ran from 2003 through 2014.

 

[brian_]

Terminology

It would be nice if someone fixed whatever online translation tool is turning the words for electric motor in various languages into "engine" so that it produces "motor" instead. If you use Google Translate to translate "electric motor" from English to Swedish, it says "elektrisk motor"... but if you use the same tool to translate "elektrisk motor" from Swedish to English, it says "electric engine"! It's a Tesla drive unit, consisting of a motor, transmission with differential, and inverter.

 

[brian_]

Questions

Will there be any storage space under the hood in the front, or will that space all be taken by the charger, DC-to-DC converter, and other equipment?

I assume that to complete the battery packaging, there will be a metal box built around the modules, to enclose them and to provide a load floor inside.

 

[Steel]

Yabert, hope that In sweden its a typical " craftsman car" people doesn´t expect sportscar performance. But the reason I build it, it´s because I want to build a car I can use.

Brian_thank you ! I will try to improve my english

It will all be covered with aluplates. Tearing it all apart now for painting, also making a box over the motor for all electrical equipment. Using Tesla original cables, best position to make it fit was on top of motor.

No plans for original engine compartment, maybe put in a REX

BR Pär

 

[brian_]

I will try to improve my english

No problem; your English is far better than my Swedish! The only problem is with those online translation tools... but I suppose I shouldn't complain about something that is offered free of charge.

 

[brian_]

... also making a box over the motor for all electrical equipment. Using Tesla original cables, best position to make it fit was on top of motor.

I assumed that equipment would be in front in a Tesla - is it normally in the back, or is this a Tesla front motor?

It would be nice to keep a flat load floor in the van, rather than having a box above the rest of the floor level.

 

[Steel]

Hello, I agree brian_, a box on top of the motor is not the best. But if I want to use original cables it had to be like that. And I had to make some sort of hood over motor anyway and also some box for electronics. Now it will be " två flugor i en smäll " translate that in google

It´s a rear drive unit from Tesla, normally high junction box and charger lies under rear seat in a Tesla.

BR Pär

 

[brian_]

Now it will be " två flugor i en smäll " translate that in google

Hello, I agree brian_, a box on top of the motor is not the best. But if I want to use original cables it had to be like that. And I had to make some sort of hood over motor anyway and also some box for electronics. Now it will be " två flugor i en smäll " translate that in google

It´s a rear drive unit from Tesla, normally high junction box and charger lies under rear seat in a Tesla.

Thanks
That's one of those details that the Tesla fans forget to mention when they brag about the clean and simple "skateboard" design.

 

[Steel]

_brian.

I´m designing box for Charger, HJVB, BMS and VCU. Not the best for loading , as _brian mentioned, but it must be like this when I want to use original cables. Also charger and HJVB is not IP65 protected, must be in a inclosured enviroment. Found a nice box for VCU and BMS also.

 

[Steel]

Hello, finished box today. Used wooden plate to bolt everything in place.
Tomorrow I`m going abroad to pick up some nice conversion parts in a land blessed with EV´s.

 

[tylerwatts]

That is looking very smart. It will perform very well I think.

May I suggest you build the lid on the box all the way out to the sides of the van so you have a full flat surface to load stuff on etc. If there is a step in front on the box it is not a big problem but having a small space all round the box will be awkward for loading in the van etc.

 

[Steel]

tylerwatts, I agree, must make something, not smart to have small space all round. Things will get stuck and be missing.

Home again from my 900 km trip to Norway picking up EV OEM conversion parts.
Went to Grönvolds Bildemontering in Brumundal and made business with Tom Grönvold. Very nice guy, told me he was selling Tesla parts all over Europe but mostly to Nederlands and Germany.
Picked up a Tesla EU chargingport and HJVB. But also a BMW I3 motor, driveshafts and batterypack But thats for my next projekt, Fox Reliant !

BR Pär

 

[Ada Diamonds]

Really impressive project!

What are the goals for the finished project? What are the interior plans?

 

[Steel]

Ada Diamonds : First of all make it street legal throu SFRO a Swedish organization formed to help amateurs to build cars and get them legal. Outside spoilers and paint. Inside no plan so far.

Unloaded parts yesterday, I3 motor, batterypack, driveshafts and gearshifter.

For Vito projekt EU chargeport, cables and HJVB.

BR Pär

 

[Steel]

Hello, put the chargingport i place. Also prepared some cable mangement and mounting plate for HJVB. I intend to weld all mounting plates etc before tearing apart and paint.
Must find some gromits for cable and vaterhoses.

BR Pär

 

[Kevin Sharpe]

Also prepared some cable mangement and mounting plate for HJVB.

Are you aware that you're missing the box that switches between 1 and 3 phase AC? It's fitted to the HVJB on the opposite side to the Charger. You can see it in the attached photo.

I have one on route to me and will produce a schematic in a week or so. You may want to review the HVJB schematic (here) before turning on the power

 

[Steel]

Thank you, Kevin Sharpe ! I was not aware of that. I assumed it was split up in HVJB.
It means that 3 phase charging is an option.
I bought charging port, cables and HVJB as a complete set and thought I was fine with that.

If I want to look for one box, what is i called ??

BR Pär

 

[Kevin Sharpe]

If I want to look for one box, what is i called ??

I can find no reference to the 'box' in the Tesla service manuals and parts lists... I'll publish the part number when it arrives. I also need to understand how Tesla supported both 1 phase and 3 phase charging on the dual charger setup (afaik the 'box' only supports a single charger )