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by jonescg
Today, 17:20
Forum: Technical and conversion discussion
Topic: Prelude conversion project - some questions
Replies: 699
Views: 78373

Re: Prelude conversion project - some questions

New Pack built sml.jpg
New Pack built sml.jpg (183.94 KiB) Viewed 12 times
Just patching up the cover and will be ready for an install very soon.
by jonescg
Wed, 03 Mar 2021, 14:36
Forum: Technical and conversion discussion
Topic: Prelude conversion project - some questions
Replies: 699
Views: 78373

Re: Prelude conversion project - some questions

It's still going to be a rush to get things ready for Saturday... The battery cover certainly won't be waterproof in time, but I might be able to get the internals finished.
clamps.jpg
clamps.jpg (147.35 KiB) Viewed 69 times
by jonescg
Mon, 01 Mar 2021, 20:57
Forum: Hyundai and Kia
Topic: Brake Lock: it should not happen!
Replies: 5
Views: 125

Re: Brake Lock: it should not happen!

I did hit the picks on a gravel road in the Ioniq and found it was really bad at pulling up. Felt like it locked up and pushed a pile of gravel in front of the tyres... But it should be better on bitumen surely?
by jonescg
Mon, 01 Mar 2021, 20:53
Forum: Technical and conversion discussion
Topic: Prelude conversion project - some questions
Replies: 699
Views: 78373

Re: Prelude conversion project - some questions

I will need some of that stuff yes. It's used on bathroom tiles right? I will need to hack and modify bits of the cover to make everything fit regardless, so once that's done I'll get busy with the sealant.
by jonescg
Mon, 01 Mar 2021, 19:39
Forum: Technical and conversion discussion
Topic: Prelude conversion project - some questions
Replies: 699
Views: 78373

Re: Prelude conversion project - some questions

The front busbars are going to be fairly easy to put together, but it does mean that the battery clamps will need to be as tight as practical, and as close to the modules as I can get them. There's barely a 1.6 mm gap there, so I'll have to ensure a sheet of FR4 sits in front of the busbars to preve...
by jonescg
Sun, 28 Feb 2021, 20:50
Forum: Technical and conversion discussion
Topic: Prelude conversion project - some questions
Replies: 699
Views: 78373

Re: Prelude conversion project - some questions

brendon_m wrote: Sun, 28 Feb 2021, 18:01 Looking good.
Hope to see it at electrikhana
Everything will need to go right, but we'll see how we get on.
by jonescg
Sun, 28 Feb 2021, 16:59
Forum: Technical and conversion discussion
Topic: Prelude conversion project - some questions
Replies: 699
Views: 78373

Re: Prelude conversion project - some questions

All I need now is the sheet metal clamps.
almost reassembled.jpg
almost reassembled.jpg (99.16 KiB) Viewed 145 times
almost reassembled2.jpg
almost reassembled2.jpg (191.96 KiB) Viewed 145 times
It's T I G H T... I think I'll be doing some fibreglassing on the enclosure to make it fit.
by jonescg
Sat, 27 Feb 2021, 20:53
Forum: Technical and conversion discussion
Topic: Prelude conversion project - some questions
Replies: 699
Views: 78373

Re: Prelude conversion project - some questions

Last weekend I welded every last cell and glued the top and bottom covers on. Today was supposed to be the day I filled them with potting compound - EPL-9 which is a polyurethane elastomer with a hardness ideal for keeping batteries snug. My plan was to drill out the missing cell and use this as a f...
by jonescg
Sat, 27 Feb 2021, 17:11
Forum: Fonzarelli
Topic: Fonzarelli sale on at the moment
Replies: 2
Views: 1699

Re: Fonzarelli sale on at the moment

They did have the guys in North Perth set up, but sure if they followed through with it though.
I rode the NKD - did not like. The steering geometry is all horribly wrong. Talk it up as 'nimble' all you like, but it steered like a trolley. Power was fine for the job at least.
by jonescg
Sat, 27 Feb 2021, 13:31
Forum: Batteries, charging, management and monitoring
Topic: E-Moto battery connectors melting....
Replies: 5
Views: 108

Re: E-Moto battery connectors melting....

Hmm, no images showing up. Chinese made stuff is often undersized on the connectors. It would need to be a minimum of 16 mm2, preferable 20 mm2 for the power of the bike.
by jonescg
Sat, 27 Feb 2021, 09:59
Forum: Technical and conversion discussion
Topic: Planned Suzuki Jimny conversion
Replies: 44
Views: 1042

Re: Planned Suzuki Jimny conversion

I only put the Prelude build in the technical section because it wasn't my machine... But it sort of belongs there anyway.
by jonescg
Wed, 24 Feb 2021, 19:46
Forum: Technical and conversion discussion
Topic: Planned Suzuki Jimny conversion
Replies: 44
Views: 1042

Re: Planned Suzuki Jimny conversion

I don't know much about it myself to be honest, other than to say that three 7 kW on-board chargers and a Type-2 inlet would make more sense. If you have room for them of course.
by jonescg
Mon, 22 Feb 2021, 15:56
Forum: Batteries, charging, management and monitoring
Topic: 12-cell CAN-based BMS modules
Replies: 13
Views: 2936

Re: 12-cell CAN-based BMS modules

SEI is both necessary to protect the anode, and unfortunate as it depletes the lithium inventory. Crud has to come from somewhere, and the mobile Li+ ions are a good source. So gains in the SEI means losses in mobile ion stock. Net result is lower useable capacity and higher internal resistance. If ...
by jonescg
Sun, 21 Feb 2021, 14:42
Forum: Batteries, charging, management and monitoring
Topic: Normal/Acceptable Battery Sag?
Replies: 4
Views: 544

Re: Normal/Acceptable Battery Sag?

Work out what the DCIR of the cells are first.
0.5 V / 200 A = 2.5 mOhms. Not bad.

So if you had a nominal 96 of them in series for a typical 355 V system, your total DCIR might be 0.24 ohms.
200 amps at a nominal 355 V is 71 kW, but I^2 x R losses mean you're generating 10 kW of heat!
by jonescg
Sat, 20 Feb 2021, 22:31
Forum: Technical and conversion discussion
Topic: Prelude conversion project - some questions
Replies: 699
Views: 78373

Re: Prelude conversion project - some questions

Finally, about 5 weeks after starting, I have spot-welded the last tab to the busbars. Last thing to do now is solder the 6 or 7 recalcitrant tabs which can't be welded. You can see them where I've ground back the passivated nickel surface. Then do the cell top welding (about 2 hours there) before p...
by jonescg
Mon, 15 Feb 2021, 09:08
Forum: Renewable Energy and Storage (Non-EV)
Topic: Leaf battery pack for home storage?
Replies: 18
Views: 366

Re: Leaf battery pack for home storage?

These are the ones I was thinking of. Plus the one @4Springs put together here on the forum.

ZEVA - https://www.zeva.com.au/
EV-Power - https://www.ev-power.com.au/webstore/
by jonescg
Fri, 12 Feb 2021, 15:59
Forum: Renewable Energy and Storage (Non-EV)
Topic: Leaf battery pack for home storage?
Replies: 18
Views: 366

Re: Leaf battery pack for home storage?

There are cheaper BMS's around, they just have less fruit. If fruit is your thing Batrium has it by the ... bowl full.
by jonescg
Fri, 12 Feb 2021, 10:51
Forum: Hyundai and Kia
Topic: Kona Fire - new packs required
Replies: 24
Views: 637

Re: Kona Fire - new packs required

Oooh cheap Korean home storage batteries coming to a garage near you!
by jonescg
Fri, 12 Feb 2021, 09:53
Forum: Renewable Energy and Storage (Non-EV)
Topic: Leaf battery pack for home storage?
Replies: 18
Views: 366

Re: Leaf battery pack for home storage?

You mean use the Leaf battery as is? If you can use the CAN protocol to operate the BMS, then I can't see why not. You'd need a high voltage DC hybrid inverter though. It's much easier to pull the battery apart, sort the laggards from the good cells, re-configure as a 14s pack and buy a 48 volt hybr...
by jonescg
Wed, 10 Feb 2021, 13:50
Forum: For Sale/Wanted
Topic: Electric Maserati
Replies: 9
Views: 397

Re: Electric Maserati

Volta wrote: Tue, 09 Feb 2021, 22:11 Thanks for all the info. gents. Series is the next step. As for the comment by Mr Jones are you alluding to the fact I may be over the hill? 😉😉
Tongue firmly in cheek. I'm sure you have a strong right foot.
by jonescg
Sun, 07 Feb 2021, 20:44
Forum: For Sale/Wanted
Topic: Electric Maserati
Replies: 9
Views: 397

Re: Electric Maserati

Depending on your battery voltage you might not have the top speed you want, but I'm sure you're past all that now eh Dave? ;)
by jonescg
Sun, 07 Feb 2021, 14:08
Forum: Technical and conversion discussion
Topic: Prelude conversion project - some questions
Replies: 699
Views: 78373

Re: Prelude conversion project - some questions

Ah yes true there is that approach for sure. I see a guy on Endless Sphere has bought a pulse arc welder for welding 0.4 mm thick copper to cells directly. Does a good job, and 0.4 mm thick copper is about equal in conductivity to 1 mm aluminium, with none of the intermediate resistance of a nickel ...
by jonescg
Sun, 07 Feb 2021, 13:56
Forum: Technical and conversion discussion
Topic: Prelude conversion project - some questions
Replies: 699
Views: 78373

Re: Prelude conversion project - some questions

Thanks, I just finished module #2. We had the remains of a tropical low come south to visit Perth, so while the cooler weather is very welcome, the humidity isn't quite so popular. I'm watching the busbars of the remaining two modules start to get progressively more and more passivated. Some of them...
by jonescg
Fri, 05 Feb 2021, 22:06
Forum: Technical and conversion discussion
Topic: Prelude conversion project - some questions
Replies: 699
Views: 78373

Re: Prelude conversion project - some questions

thermal epoxy going on.jpg A shot of the thermal epoxy before the FR4 goes on. I have had to contend with some passivated sections of busbar which will not take a spot weld. I can't even solder it. But as they might only impact half a dozen cells per busplate, I can't really justify making a new on...
by jonescg
Fri, 05 Feb 2021, 20:43
Forum: General EV Discussion
Topic: Future fuels discussion paper
Replies: 5
Views: 266

Re: Future fuels discussion paper

It's bollocks. Two years overdue and full of nothing. Literally seeks to just do nothing and let the market sort it out. Actively promotes 20 year old technology (hybrids) as new technology and lies about their supposed advantages. Taylors comments today were littered with contradictions. "We see no...