Dala's Leaf buildthread (2015 Nissan Leaf)

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Sammyboi
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Re: Dala's Leaf buildthread (2015 Nissan Leaf)

Post by Sammyboi » 23. Jan 2019 08:44

Dala wrote:
22. Jan 2019 12:21
I now have some capacity numbers to share, and time to make a decision.
Test, 5Amp discharge, from 4.1V -> 3.3V
USA cell: 39,77Ah
Italy cell: 43,30Ah

So presuming I have an USA cell from the same batch, If I upgrade to the Italy cell, I'd get a 9% range increase! I could also try looking for better cells, but most people just sell untested cells :/ Hmm...
Well that is truly a bummer..

There aren't that many wreckers around in Finland either, where you could go and test them yourself. You seem like a handy guy so make do and fit both of them :P

Really nice going through the troubleshooting. I have no clue about the procedures for these cars so this is definitely educational. Keep your head high!

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Re: Dala's Leaf buildthread (2015 Nissan Leaf)

Post by Dala » 10. Feb 2019 13:08

Status update on the Leaf!

I assembled the OpenEVSE unit. Now I need to decide where I mount it. I will most likely make it open to the public on all charging apps, since it probably goes in the middle of nowhere :D
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We have also had a fair bit of snow in Vaasa :D
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Due to the shitty weather, I decided to get some proper snowtires instead of the all-season ones that came with the car.

I settled on "Nokian Hakkapeliitta R3"
in the format: 205/55 R 16 94 R XL
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This is the tyre that Nokian primarily recommends for electric cars, since it's a low rolling resistance and wont impact the range. On the sticker they are branded as B on the economy gauge. The efficiency step between A - B - C goes something like 100% - 97% - 90%, so there is a huge benefit from stepping up from C to B. From B to A the 3% efficiency step is not as noticeable.

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Re: Dala's Leaf buildthread (2015 Nissan Leaf)

Post by Dala » 27. Mar 2019 15:30

I'm in the local paper!

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I'm currently in the process of starting up my own company, aiming to be the first in Finland to offer 3rd party EV battery service/swap/upgrades. It's gonna be a wild ride! :)

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Re: Dala's Leaf buildthread (2015 Nissan Leaf)

Post by Tuopponen » 28. Mar 2019 07:42

Good luck with the new business!
I think that you will made it, it's a right time for that kind of business. :thumbsup:
-Honda Civic EJ8 -97 B18C Projekti/Kesäauto
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IG: _sami_t

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Re: Dala's Leaf buildthread (2015 Nissan Leaf)

Post by Dala » 01. Apr 2019 16:15

I went and added the garage to the Plugshare map, in-case someone is close to getting stranded in the middle of the Kvarken world-heritage archipelago :D

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It sure is an EV dead-zone out here :D

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Re: Dala's Leaf buildthread (2015 Nissan Leaf)

Post by Dala » 26. Apr 2019 20:46

So, now that the weather is getting warmer, it is way more inviting to work on the car. First order of business, getting the undercoating tiptop.

This is what the stock rear wheel-well looks like
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Not very protective at all, when you run on gravel roads, the noise is awful when it slings small pebbles straight on the metal inner arch. So, I de-greased it, brushed it, rinsed it, let it dry, and applied some rust coating with a brush. It also doubles as sound deadener!
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One done, three more to go :D

Oh, and for my EV Repair company, I bought this essential tool, the 'EVs Enhanced HV Battery Paring Tool'
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Now I can swap batteries properly between cars :)

And if anyone is interested in following my FB page for my business (mods please remove if inappropriate ;) ) https://www.facebook.com/DalasEVrepair/

My end goal is to be able to sell battery upgrades, something Nissan has decided that older cars won't get at all!

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Re: Dala's Leaf buildthread (2015 Nissan Leaf)

Post by Dala » 29. Apr 2019 20:12

Another Sunday, now both rear wheelwells are protected against the elements.
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Re: Dala's Leaf buildthread (2015 Nissan Leaf)

Post by Dala » 13. May 2019 21:25

Soo, the Leaf developed a leak... quite a big one too! Not so fun to see it drip from the side airbag :D
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Tore the interior apart to investigate, it leaks on the top part
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Spread the rubber gasket with zipties, blowdried it
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Applied lots of clear silicone, let's see if it holds. If not, the windscreen needs to be resealed. Fingers crossed for an easy fix :)
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Started working on the looks. The front of this car is really "froggy". Eyelids should help the look quite significantly. Started by removing the rear piece, not used for anything.
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Wrapped the rear piece. Still need to wrap a slight amount on the upper headlight too, but let's see how the material hold up. It had a slight purple color, would have liked matt black more. Ohwell, I will iterate as I go
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Then I focused my attention to something more fun. The horn! On all the Leafs, the horn is pathetic. It sounds like a toy car. Lets fix that!

Started by removing the front splash shield, peeking up on the horn assembly from under the car
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Here is the stock Denso unit, compared to a 1991 Nissan NX horn setup. I really like 90s Nissans, so it felt like a perfect choice. The same horn setup is found in the S13 afaik!
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Horns mounted. The horns ground via the mounting bolt, so had to fashion a wiring adapter. Note the one pin that's not needed anymore.
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Here's a comparison

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Re: Dala's Leaf buildthread (2015 Nissan Leaf)

Post by Dala » 16. May 2019 12:36

The Man-in-the-middle attack CAN prototype boards from Muxsan arrived today. This thread is going to get quite technical soon...
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Re: Dala's Leaf buildthread (2015 Nissan Leaf)

Post by Dala » 23. May 2019 21:32

Now something completely different.

My friend Johan was bitten by the 3d-printing bug, and I am so intrigued! I searched thingiverse for a J1772 holder, and found this simple design:
https://www.thingiverse.com/thing:2481870

So I sent him a message, and little over an hour later, a prototype was printed.

Started
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Finished
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I was told this was a really fast prototype (Layer-height was 0.3mm), and if I wanted a better looking one it would take roughly 4.5h to print one. I am so excited by such a small piece of plastic :D Thanks Johan :)

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Re: Dala's Leaf buildthread (2015 Nissan Leaf)

Post by Dala » 31. May 2019 18:00

So let's talk wheels. Winter is long over and it's time for summer tires. This is the first car I've owned with a Tire Pressure Monitoring System (TPMS). I got a new to me set of alloys, and naturally wanted to keep the TPMS functioning. First order of business was to order another set of pressure sensors, but the local Nissan dealership had these for 100€/sensor! So ebay was naturally the next place to look, and for 17€/sensor I won't complain.

Here are the wheels fitted, stock Bridgestone Ecopias, 16", 17.1kg rims. The exact same weight as the OEM steelwheels, so not very high quality rims these. But they look better than the steelies :)
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So, let's tackle the TPMS warnings. The Leaf warns you about the TPMS on both the lower and upper instrument cluster. It also flashes them for a solid few minutes, so you'll definitely notice it and want to fix it asap!
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The solution is LeafSpy Pro. The instructions are so simple that anyone can remap the sensors. It took me 10 minutes!
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After getting the car to accept the new sensors I let it cool down for 30mins. Then I filled the tires up to the eco-miling spec of 3.1bar front, 3.0 bar rear. Instrument cluster is happy again!
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My 3d-priting obsession continues, I wanted to personalize the wheels, so 3d printing center caps seemed like a perfect tiny project.

Started by modelling this "Toyota Prius Wheel Center Cap - Power Symbol" https://www.thingiverse.com/thing:44003 to fit my wheels, made new hooks. It's so easy to model, using sketchup since it's free.
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Printed a prototype, worked almost too good, now to print more in higher quality and paint them :)
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I promise I'll get back to the CAN stuff soon, just wait ;)

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Re: Dala's Leaf buildthread (2015 Nissan Leaf)

Post by Dala » 16. Jun 2019 14:12

Now here's some progress,

I took delivery of the first batterypack from Norway! It was dusty, came from a crashed 30kWh Leaf. Shipping from Norway->Finland was only 200€!
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After getting it home and cleaning it up, the label identifies it as a 30kWh pack made in the UK.
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After splitting the case open. You can already spot the big doublestacked modules! The complete battery weighs rougly 20-30kg more than a 24kWh battery!
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Next on the agenda is to extract all the modules! NOTE, I am not going into detail on the safety aspects since they will differ from country to country. 400VDC can kill, always get certified (SFS 6002 FIN), attend safety trainings and use the correct safety gear when dealing with high voltages.

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