My Dusty 71 GMCe Electruck

[Gregski]

once those three are individually loaded and bolted up, we simply flip that batch over - right side up

[Gregski]

and now we are ready for the top batch

[Gregski]

and there we have it, "The Stack" configuration (genius I tell yah, genius!)

[Gregski]

now every battery pack has it's pros and cons, be it a Tesla pack, a Nissan Leaf, or this BMW 530e, and this one is no different, one of the downsides of it is these unobtanium proprietary high voltage cables, it is a real challenge to reconfigure the standard pack layout whilst utilizing only the stock high voltage cables

some like this one joins two cell modules very smartly.... (we like, we approve)

[Gregski]

by Gregski » Mon May 02, 2022 7:57 pm

here is one BMW 530e battery pack (Embedded Fun Fact: which consists of six cell modules, unlike the 330e which only has five) reconfigured in The Stack Formation, unfortunately we are unable to complete this arrangement because we are one cable short, technically we have the cable but it is just too short to join Cell Module #2 to Cell Module #3

[Gregski]

Ladies and Gentlemen, the Battery LifterUpper (TM)

[Gregski]

I'm a Simple Man, I see a gap... and I fill it!

[Gregski]

yes we did run out of gas... (no literally)


but we recovered, and one side's done

[Gregski]

and onto the other side, having the frame rails level now is a total game changer


man I love a clean canvas

[Gregski]

alright, let's load 'em up proper

[Gregski]

now I currently only have one pack installed here, but hopefully you'll get the idea how this design is meant to hold two of them, six cell modules on top and anther six upside down

this will yield 18.2 kWh

so at 3.5 miles per kWh we guestimate a range of 63.7 miles

keep in mind this is just a start, I can install more batteries under the bed

[jimbosprint]

Excellent progress. I'll have to stop by to check this out in person next time I drive that way.

[Gregski]

Originally Posted by jimbosprint

Excellent progress. I'll have to stop by to check this out in person next time I drive that way.

Thank you, Indeed! bring your wire wheel, this purple paint aint gonna fall off by itself, ha ha

[Gregski]

so time to make a List for Phase I as I plan on doing or should I say NOT doing some stuff in this Phase that may be a bit controversial

PHASE I PROGRESS REPORT

1. Mount Lexus transmotor - ✔
2. Install modified Lexus drive shaft - ✔
3. Mount transmission fluid pump controller
4. Mount Lexus inverter - ✔
5. Mount Honda CRV brake booster - ✔
6. Install Toyota Prius power steering column - not happy with this install (my job, not the part)
7. Install first BMW 530e battery pack - ✔
8. Lay down the Controller aka VCU on the floor inside the cab
9. Install modified BMW 530e pre charge circuit aka "Safety Box"
10. Install Chevy Volt first gen DC-DC converter
11. Install BMW E46 throttle pedal
12. Install B&M transmission floor shifter
13. Install Tesla Model S water pump

Not happening in Phase I

1. Lock input shaft in the Lexus transmotor*
2. Install onboard battery charger**
3. Install Battery Management System aka BMS***
4. Install customized digital gauges
5. Install second BMW 530e battery pack

the Controversial Section (we can thumb wrestle over these items if you like - by appointment only, ha ha)

* Input Shaft, I want to dyno test the truck with only MG2 powering the rear wheels to see how much horse power it actually puts out in real life

** no Charger, this is the first of the radical ideas, why do we need a battery charger mounted on board permanently, isn't that the equivalent of driving around with your very own gasoline/petrol pump, can you imagine pulling up to SHELL or Chevron with your own pump mounted in the back of your truck?

*** no BMS, eventually I plan on getting SimpBMS but it is just so expensive here in the States, I think they want $650 for the hardware

[Gregski]

Originally Posted by LT7A

Ok, I see... But don't you only need one? I mean, won't it be hardwired in and so that the others will just sit on the shelf? Or are you going to try each of them out and see which one works best? Or are you starting a collection? Not trying to be silly.. okay maybe a little bit.. but definitely curious why you have so many.

Ok, I can only drive one truck at a time, and that hasn't stopped me from getting... uh, more than one... so no implied criticism, just curiosity.

excellent questions, I bought so many chargers to teach myself how they work by comparison

at first when I bought the Tesla charger I thought I could pull up in my converted electric truck to a Tesla charging station and charge, but that's not how it work's Elon Musk prevents you from doing just that, the charging station for a lack of a better term senses your car and you have to be in a genuine Tesla to use it


~ CONTROL VIA HARDWARE~
the other thing I learned is that donor EV components such as the chargers are controlled in one of two ways, either you have to lobotomize them, essentially rip out their logic board and replace it with a reverse engineered one, this is how the Tesla charger works


~CONTROL VIA SOFTWARE Type 1~
Or, you can control the charger in it's current original OEM shape without changing any of the hardware simply by learning what CAN Bus commands it needs to operate, that's how the Chevy Volt first gen charger works


~CONTROL VIA SOFTWARE Type 2~
another way to control a charger in it's OEM hardware form simply by using software is by figuring out what PWM signal to send to it, PWM aka Pulse Width Modulation, this is how the Chevy Volt second gen charger works

hope this helps

[Gregski]

another day another mock up, and I'm loving how it's turning out

[Gregski]

as much as I love this BMW 530e hybrid battery pack, it's Achille's heel has got to be the proprietary high voltage terminals, which call for the unobtanium plugs and wires, here I am trying to figure out how to use only the stock amount of high voltage cables to rewire it flat instead of two cell modules stacked on top like in the original implementation

[Gregski]

no I didn't just spend 4 hours drilling two holes in the most unreachable of places, who in their right mind designed these silly frame extensions?!?!

[Gregski]

tell me you're done with Fab without telling me you're done with Fab

[Gregski]

finally... no more Purple (sorry Prince, R.I.P.)

[Gregski]

the transmission crossmember also got sum red luv in our outdoor free range organic make shift paint booth

Bonus Points for clever use of not only exhaust pipes but exhaust U clamps, not like we're going to be needing them again

[72 tigger]

Painting =progress!!

[zicc1835]

Originally Posted by Gregski

the transmission crossmember also got sum red luv in our outdoor free range organic make shift paint booth

Bonus Points for clever use of not only exhaust pipes but exhaust U clamps, not like we're going to be needing them again

Looks like you EXHAUSTED some of your enginenuity to get this done🤭

[Gregski]

Originally Posted by 72 tigger

Painting =progress!!

indeed!

[Gregski]

Originally Posted by zicc1835

Looks like you EXHAUSTED some of your enginenuity to get this done��

well played, you're not just blowing smoke that's fer sure