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Post by gregleaf on Jan 8, 2017 17:34:39 GMT 11
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Post by gregleaf on Jan 8, 2017 19:11:17 GMT 11
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Post by gregleaf on Jan 8, 2017 19:12:54 GMT 11
This is the new cable which was made up using the original connections. It goes between the Brusa output and the inverter
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Post by gregleaf on Jan 8, 2017 19:13:42 GMT 11
It is now covered in Orange split conduit
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Post by iamlsd on Jan 10, 2017 20:19:39 GMT 11
Wow big project - Thanks for sharing your progress so far. Can't wait to see the rest and perhaps a rough cost estimate.
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Post by 4wardthinking on Jan 11, 2017 9:07:48 GMT 11
Out of curiosity here. The LEAF can chargeat 3.3kw standard, yet you are replacing it with one of similar potential. Why?, I considered the 7kw change on ours, but warranty feasibility & $'s changed my mind. I've only charged ours st 3.3 four times, and admittedly, the time to charge was markedly faster, but reality suggested it wasn't really advantageous. It's not too difficult to do, with careful workmanship. I have!! taken the line of larger(more potent) electric motor though, and this probably, in my case could be better dollars spent. It would/could be used more often  |
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Post by gregleaf on Jan 11, 2017 9:12:21 GMT 11
Out of curiosity here. The LEAF can chargeat 3.3kw standard, yet you are replacing it with one of similar potential. Why?, I considered the 7kw change on ours, but warranty feasibility & $'s changed my mind. I've only charged ours st 3.3 four times, and admittedly, the time to charge was markedly faster, but reality suggested it wasn't really advantageous. It's not too difficult to do, with careful workmanship. I have!! taken the line of larger(more potent) electric motor though, and this probably, in my case could be better dollars spent. It would/could be used more often I am adding a second charger in parallel not replacing the original. It will increase the peak charging rate to approximately 7Kw. |
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Post by gregleaf on Jan 11, 2017 9:13:45 GMT 11
Wow big project - Thanks for sharing your progress so far. Can't wait to see the rest and perhaps a rough cost estimate. I picked up the Brusa for approximately $750Au second hand on eBay. New they cost $3500 AU |
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Post by 4wardthinking on Jan 11, 2017 9:18:12 GMT 11
Out of curiosity here. The LEAF can chargeat 3.3kw standard, yet you are replacing it with one of similar potential. Why?, I considered the 7kw change on ours, but warranty feasibility & $'s changed my mind. I've only charged ours st 3.3 four times, and admittedly, the time to charge was markedly faster, but reality suggested it wasn't really advantageous. It's not too difficult to do, with careful workmanship. I have!! taken the line of larger(more potent) electric motor though, and this probably, in my case could be better dollars spent. It would/could be used more often I am adding a second charger in parallel not replacing the original. It will increase the peak charging rate to approximately 7Kw. Ah. Ok, that part I missed. |
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Post by gregleaf on Jan 28, 2017 13:23:24 GMT 11
  We had some success today. We managed to get the Brusa charger to operate in Auto mode and preprogrammed 2 stages of a possible 5 stages. We were then able to charge with the Brusa at 16 amps at the same time as charging at 10 amps via the original J1772 inlet. At this stage we haven't got a second J1772 inlet working, just a mains power cable to the Brusa. |
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Post by gregleaf on Jan 28, 2017 13:26:40 GMT 11
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Post by gregleaf on Jan 30, 2017 17:18:56 GMT 11
  I spent 2 hours yesterday removing the old black powder coating from the Brusa cover that was blistered and pealing. Today I sent it off to have a textured silver powder coating applied. |
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Post by gregleaf on Feb 6, 2017 22:35:44 GMT 11
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Post by gregleaf on Feb 6, 2017 22:37:22 GMT 11
The refurbished Brusa cover and new badges.
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Post by gregleaf on Feb 6, 2017 22:40:33 GMT 11
 The power cable has been tidied up. Next up will be to add a second J1772 in the place of the current CHAdeMO inlet and relocate it to under the hood. I am also installing a Mennekes inlet |
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Post by gregleaf on Feb 8, 2017 9:08:39 GMT 11
 Yesterday I had this adapter made up by Danny Ripperton to accommodate a second J1772 inlet in the place of the original CHAdeMO inlet, which will be relocated to under the bonnet with a Mennekes inlet to facilitate Tesla destination charging without a adapter. On a side note, I discovered that removing the CHAdeMO inlet is enough to throw enough error/warning lights on the dashboard to light up a small Christmas tree when you try to drive without it plugged in. (See next picture). The car is also unable to be placed in D/Eco/R.  |
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Post by gregleaf on Feb 8, 2017 9:12:43 GMT 11
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Post by markrmarkr on Feb 8, 2017 11:44:30 GMT 11
I'll have to see all this this afternoon. Looking real good Greg.
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Post by gregleaf on Feb 19, 2017 17:39:29 GMT 11
 This image is of the relocated CHAdeMO connector and the Mennekes (Tesla style) connector that have been located on a custom made bracket under the hood. |
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Post by gregleaf on Feb 19, 2017 17:41:40 GMT 11
 This is the second J1772 inlet, located in the old CHAdeMO spot. I can now charge via both J1772 inlets simultaneously, with approximately 7Kw. |
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Post by gregleaf on Feb 19, 2017 17:45:45 GMT 11
 This is the CHAdeMO/Mennekes bracket in the process of being made. Many thanks to Danny Ripperton. Many hours of work in it's design and manufacturing. |
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Post by duncan on Mar 16, 2017 19:56:02 GMT 11
Absolutely awesome work, I know exactly how difficult custom fabrication can be and you guys have done a great job One very important issue I've probably missed; did you retain the factor DC/DC charger for the 12v battery and only replace an empty cover or are you 12v charging-less? |
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Post by gregleaf on Apr 12, 2017 13:03:12 GMT 11
The DC DC converter has been retained. The inverter cover has been removed to make space for the Brusa charger.
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Post by gregleaf on Apr 23, 2017 20:30:19 GMT 11
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