Re: My Dusty 71 GMCe Electruck
 

Ah Yeah! The Crimpulator 3000 is here! not bad for $32 bones on AMAZON

Re: My Dusty 71 GMCe Electruck
 

and so we got to work on my test battery cables, I decided to add a little color coding to the two solid orange main leads, first some black heat shrink tubing went on both ends of the negative cable

for this I needed a bunch of yellow tools

Re: My Dusty 71 GMCe Electruck
 

and here is what the six cell modules look like all connected just the way they were inside the 2018 BMW 530e high voltage battery pack

Note the short orange wire on the far right, that's was the original main Positive lead that came off of Cell Module # 6, I decided to replace it with the same orange wire that runs from Cell Module # 1 on the left (that is what the original looked like) so now both leads match

One lead was originally shorter than the other. BMW did that because the leads ran to the Safety Box which was located on the right side of the battery pack closer to Cell Module # 6

Re: My Dusty 71 GMCe Electruck
 

Nice clean end of the run on that cable. I'd never have a use for a crimping tool like that, but for 32 bucks seems like a good deal!

Re: My Dusty 71 GMCe Electruck
 

thanks, no doubt, they messed up on two counts, first here's what I paid and here's what it is today

for the record they played the "Your order is delayed game with me, in a failed attempt to get me to cancel it"

Re: My Dusty 71 GMCe Electruck
 

and check this out, this is what I ordered and this is what they shipped

Re: My Dusty 71 GMCe Electruck
 

think positive

Re: My Dusty 71 GMCe Electruck
 

and here is the completed DC wire harness with an Anderson SB120 connector in red

Re: My Dusty 71 GMCe Electruck
 

i heart this battery pack


[what? .... too soon!]

Re: My Dusty 71 GMCe Electruck
 

and how do you plan on charging this BMW battery pack?

Re: My Dusty 71 GMCe Electruck
 

Why, by using this 34 lbs Tesla Model S Gen 2 charger of course!

Re: My Dusty 71 GMCe Electruck
 

so since I am going the Open Source (pronounced: "Used Electric Car Parts") route we need to open up this Tesla onboard battery charger and perform a lobotomy on it by replacing it's "logic" circuit board with an open source one, see how that works?

The open source circuit board fools the charger into thinking it is still in the Tesla vehicle and that everything is honkey dory and we can charge.

Re: My Dusty 71 GMCe Electruck
 

then we bag 'n' tag the evidence

Re: My Dusty 71 GMCe Electruck
 

and because there was an electronic parts shortage during the filming of this movie, I had to harvest some connectors off of the old original logic circuit board and transfer them to the new board

Fun Level = -2

Re: My Dusty 71 GMCe Electruck
 

mandatory Stare and Compare of the old Tesla logic board and the new "naked" open source one

and by naked I mean not fully built yet

Re: My Dusty 71 GMCe Electruck
 

here's all the krap that has to go on the new Tesla charger circuit board, the red thing is a WiFi card (pretty cool) the old board did not have WiFi

Re: My Dusty 71 GMCe Electruck
 

patient on the operating table

Good News: you are not working with grease

Bad News: you have to go all Inspector Gadget on the tiny components

Re: My Dusty 71 GMCe Electruck
 

If you are into this kinda electronics junk, check out my more deeper into the weeds build thread on the DIY Electric Car forum, link below:

1971 GMCe Lexus GS450H BMW 530e Tesla Model S powered Electruck

Re: My Dusty 71 GMCe Electruck
 

so once I had the new logic board, it was time to cabalize the charger, so first I made a simple 120 volt power cord for it

Re: My Dusty 71 GMCe Electruck
 

this Tesla onboard charger is actually three chargers in one, what I mean by that is that it has three power modules in it, each one capable of charging at 15.5 amps

think of it like three laptop AC adapter bricks side by side by side, ha ha

Re: My Dusty 71 GMCe Electruck
 

so in order to feed power from the wall into all three modules, I could do something like this

and before you file that OSHA safety complaint report, you kind Whistle Blower keep in mind this is for TESTING only

Re: My Dusty 71 GMCe Electruck
 

I did put my Big Boy Pants on later on and upgrade to an Anderson SB50 connector

Re: My Dusty 71 GMCe Electruck
 

and for those on the edge of your seats screaming, WHAT, you plan on charging those batteries using that measly 120 volt power cord that will take forever

OK, let's build a 240 volt washer and dryer cord for it as well, jeez

Re: My Dusty 71 GMCe Electruck
 

and if we want to power up all three modules

Re: My Dusty 71 GMCe Electruck
 

OR we can step it up to an Anderson SB50 connector like we did with the 120 volt one like so

and yes this is all still just for TESTING

Re: My Dusty 71 GMCe Electruck
 

yes I will go full on J1772 socket power cord for the final build

Re: My Dusty 71 GMCe Electruck
 

so here I was dinking around with 120 volt single power module charging

remember that red Wifi card on our open source logic board, well that's what the laptop is for it is talking to the charger using Wifi so that we can configure it and see how the charging is going, pretty cool stuffing

Re: My Dusty 71 GMCe Electruck
 

and here I'm trying 120 volt charging using all three power modules

YES, the wife INSISTED I do this in the comfort of our fine dinning room, so who was I to refuse her wishes

Re: My Dusty 71 GMCe Electruck
 

You better not scratch the floor! :lol:

Re: My Dusty 71 GMCe Electruck
 

ha ha, I would be doing her a favor, there's nothing wrong with it, so of course she hates it and wants a different one, married life huh?

Re: My Dusty 71 GMCe Electruck
 

:lol::lol::lol:

Re: My Dusty 71 GMCe Electruck
 

My wife wanted to change the hardwoods in the house we bought in March, they had litterally just been refinished like 3 days before we made an offer on it.. she's since re changed her mind.

But the topic at hand, pretty dang neat! I gotta admit I've been kind of stubborn/ignorant to EV stuff. I work for a public utility fleet and have been doing a lot of research lately into possible options for our fleet and I see there is definitely a use for it, and hot rodding is hot rodding!

Re: My Dusty 71 GMCe Electruck
 

I can appreciate that, and the shift has happened multiple times throughout history

horse drawn carriage => to steam car (around 1850s)

steam cars => gasoline powered engines (cause you know sitting behind 30 gallons of hot steam was dangerous, lol, so let's put 15 gallons of gasoline behind our seat)

gasoline powered cars => electric cars (it's inevitable)

Re: My Dusty 71 GMCe Electruck
 

Loving this build. Most of it is way over my head but very interesting. Near where I work is a Tesla model 3 with paper plates stillthat went off the road and has been sitting there for about six months. I don’t have any desire to start scrapping it yet though��

Re: My Dusty 71 GMCe Electruck
 

thanks, and buy it and flip it for 3x what you pay for it when you part it out, the rear wheel drive unit aka motor/inverter combo is worth big bucks, the subframe it mounts to adds even more value, the batteries (which I assume are near 100% capacity) are super desirable as is the onboard charger, hewk buy it and sell it for 2x as a whole

The Tesla Model 3 is the world's number 1 selling 100% electric car, they surpassed the Nissan Leaf already!

Re: My Dusty 71 GMCe Electruck
 

looks like Tanner doesn't want me to sell Dusty's old seats on Craigslist

Re: My Dusty 71 GMCe Electruck
 

Nice work! That SB50 connector looks like what my kids powerwheels battery uses to charge.

Re: My Dusty 71 GMCe Electruck
 

thanks, and that's cool, the red one is an SB120 and I pick them based on the fattest wire gauge I can shove in them, so

SB50: 6-16 AWG

SB120: 1-6 AWG

Remember that the smaller the AWG (gauge) number the fatter the actual wire, so it's bass ackwards.

Re: My Dusty 71 GMCe Electruck
 

spit ballin' some battery pack formations

this is the Upside-Down Cake design

Re: My Dusty 71 GMCe Electruck
 

then we stack the second layer on top, this one right side up, planning on using some T aluminum and L aluminum angle brackets in between the six modules