RXV Leaf Gen 1 to Leaf e+ Upgrade Build Thread

[mccainc]

OBC installed, wiring cleaned up. Now I’m waiting on the 2ga cables to arrive for battery install. Also have a Navitas controller on the way.

The packs are connected in series via a Nissan factory bus bar that was included in the buy. It’s a slick setup, I’ll post a pick when installed.

The project box came from Amazon, it’s called LeMotech ABS junction box. Sold in several different sizes. Sounds like a great system you’re building, are you doing it from scratch?

[Volt_Ampere]

I designed the system from scratch about 4 years ago. Spent about a year building and modifying it. Now I am duplicating it for a second cart. It's run by an AVR processor (arduino pro mini) The BMS portion is two boards each monitoring 7 cells. A third board contains the processor and communication stuff. There is a remote display for the speedometer / odometer, cell voltages, date, time, temperature, and SOC. There is a very loud alarm in the display that warns of any low cell voltages. The BMS monitors cell voltages during charging and will interrupt the charge current if any cell goes above 4.1Volts.

[mccainc]

Finally got the new 2ga battery cables installed on Friday, and the Navitas controller today. Pics with and without decorative top on the batteries. I’m thinking about making a replacement for the plastic controller/solenoid cover out of the same black diamond plate, I think I have some left over. We’ll see what my motivation is like while I wait for some other cosmetic upgrades to arrive from All Sports. Overall I’m pretty excited with how it all turned out. These batteries are a great option for anyone considering a lithium upgrade and are willing to do a little of their own work. The pigtails make it easy to integrate with whatever BMS you choose. I spent a lot of extra time making it pretty and adapting my old BMS, but if you skipped the niceification and used something more standard like a Zeva or Chargery, it would be a simple install. I’m going to have to wait for warmer weather for a range test, but initial romps around the neighborhood are exciting. Right out of the box the battery/Navitas combination had the cart doing 36mph in my short neighborhood blocks, and I don’t even have the dealer app [yet] or on-the-fly programmer. It looks like the default current limit setting on the controller is ~240A. I’m excited to see how it performs when I start cranking it up.

[Volt_Ampere]

Nice! Where did you get the piece you put on top of the batteries? Looks nice. Boards for my BMS should arrive today. I am still planning how I will mount the batteries. I will probably start work in a couple of weeks. Waiting for the average temps in my garage to get up a bit. I plan to remove the battery tray to clean things up from the mess the FLA batteries made before I got the cart. I will do my battery mounting with the tray out of the cart - then install it. I also have to pull the diff, disassemble it to do the brake discs.

[mccainc]

I got it from Lowe’s, they have some 12”x24” pieces that come pre-coated black. Mounting batteries with the tray out of the cart will be much easier, just find a friend to help you get it back in! Do you have any plans or schematics for your home built BMS? I’m very curious.

[Mike from Texas]

Following. I’m probably going to start on my install this weekend.


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[Volt_Ampere]

I will re-install the tray and then install the battery modules. I will just prep everything with the tray removed. It would not be easy to install the tray with the batteries on it. I just want to drill the mounting holes and install plates where the old batteries went since the tray is open except for the battery rails.
I have a couple weeks of prep work before I tear the cart down. I'm building my BMS now.

[Mike from Texas]

Originally Posted by mccainc

Finally got the new 2ga battery cables installed on Friday, and the Navitas controller today. Pics with and without decorative top on the batteries. I’m thinking about making a replacement for the plastic controller/solenoid cover out of the same black diamond plate, I think I have some left over. We’ll see what my motivation is like while I wait for some other cosmetic upgrades to arrive from All Sports. Overall I’m pretty excited with how it all turned out. These batteries are a great option for anyone considering a lithium upgrade and are willing to do a little of their own work. The pigtails make it easy to integrate with whatever BMS you choose. I spent a lot of extra time making it pretty and adapting my old BMS, but if you skipped the niceification and used something more standard like a Zeva or Chargery, it would be a simple install. I’m going to have to wait for warmer weather for a range test, but initial romps around the neighborhood are exciting. Right out of the box the battery/Navitas combination had the cart doing 36mph in my short neighborhood blocks, and I don’t even have the dealer app [yet] or on-the-fly programmer. It looks like the default current limit setting on the controller is ~240A. I’m excited to see how it performs when I start cranking it up.

Look great. Do you recall what size (dia/thread pitch/length) you used on the battery terminal connections. I’m thinking M8 or maybe M10 on diameter.


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[Volt_Ampere]

They're M6.

[Mike from Texas]

Originally Posted by Volt_Ampere

They're M6.

Thanks. It there a length limitation? I’m thinking 20mm length would be plenty to go through a 1/0 crimp lug and have plenty of thread engagement into the terminal.


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