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Unread 12-11-2017, 10:15 PM   #21
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Default Club Car Onward Leaf Lithium conversion

So I finally had a chance to pick it back up. I only had a couple hours but some progress is better than no progress. I got the 2 BMS12 and EVMS lite mounted, put the wire sheathing on the temp sensor wires and made the CAN cable for the LCD screen. I ran out of the CAN cable to make the charger wire, and to my surprise I couldn't find a network cable laying around so I called it a night. I'll grab a network cable at work tomorrow and get the charger wiring finished up and put the sheathing on the 2nd BMS12 tap harness. Then I should be able to bench test it on Wednesday and hopefully install this weekend.

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Unread 12-11-2017, 10:36 PM   #22
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Default Re: Club Car Onward Leaf Lithium conversion

For those that may ultimately build a pack using the same hardware, here is the PDF of the final tap harness drawing. The one I originally posted was revised twice to get to this final draft.
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File Type: pdf Onward Lithium 4 Double-Cell Pack - Tap Harness.pdf (153.4 KB, 0 views)
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Unread 12-12-2017, 08:45 AM   #23
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Default Re: Club Car Onward Leaf Lithium conversion

Great work! Show us a picture of your charger.
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Unread 12-12-2017, 10:20 AM   #24
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Default Re: Club Car Onward Leaf Lithium conversion








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Unread 12-12-2017, 10:27 PM   #25
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Default Re: Club Car Onward Leaf Lithium conversion

Got some more done tonight. Finally all of the CAN wiring is DONE!!! Iím sure glad thatís over with. All I need to do now is run the wires from the distribution block on the charger to the pack and make up the 2ga main pack cables with the big Anderson plug. Hoping to get through that tomorrow and bench test it.

Taking much longer than I anticipated. Frankly I donít even want to know how many hours I have wrapped up in this entire project from research, to sourcing parts and building. Probably well over 100 hours at this point. But Iím happy with the results so far. Fingers crossed when I do actually plug it all it it doesnít explode.












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Unread 12-12-2017, 10:33 PM   #26
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Default Re: Club Car Onward Leaf Lithium conversion

Looks awesome! Your attention to detail is noticeable and will the hours put on shows.

I can wait to hear results!
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Unread 12-12-2017, 10:58 PM   #27
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Default Re: Club Car Onward Leaf Lithium conversion

Thanks NCPW!! I figure I’m this deep, might as well try and make it look fancy. Plus messy wiring is a pet peeve of mine. Right up there with squeaky brakes and streaking windshield wipers.


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Unread 12-12-2017, 11:07 PM   #28
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Default Re: Club Car Onward Leaf Lithium conversion

Oh one thing I forgot to mention, which I think is a valuable bit of insurance when assembling the pack. Per PingEye3ís suggestion I put Blue loctite on all of the busbar bolts. That will guarantee it is a maintenance free pack.


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Unread 12-13-2017, 07:39 AM   #29
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Default Re: Club Car Onward Leaf Lithium conversion

Quote:
Originally Posted by E36Racer View Post
....Plus messy wiring is a pet peeve of mine. Right up there with squeaky brakes and streaking windshield wipers, and messy Kitchens.
I thought I'd add a little somethin' in there!

Carry on!
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Unread 12-13-2017, 11:26 AM   #30
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Default Re: Club Car Onward Leaf Lithium conversion

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Originally Posted by lockman1 View Post
I thought I'd add a little somethin' in there!



Carry on!


Lol!! My wife wants to kill me, but better than doing wiring in the garage and I do clean it all up every night. Sheís still not happy about it though


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