Naughty, that Aston Martin is sitting there waiting to be finished while you play with your toy!

This is exactly the type of technical video i was wishing for! Outstanding!

@spudproductions7606

Жыл бұрын

Thanks 👍😀

For those viewers outside of the UK, when Richard referred to "Blue Peter fashion", in terms of another battery pack, he was alluding to the famous Blue Peter phrase, "here's one I made earlier." This will also be informative to Magpie viewers who never darkened the doorsteps of Blue Peter. [If all that reads coded and whatever, just look up BBC Blue Peter and Thames TV Magpie. Children's TV programmes that live long in the adult memory]. Btw, both "classic" theme tune versions are worth listening to and are ultra nostalgic to adults returning to their childhoods.

@neilmchardy9061

Жыл бұрын

The girl on magpie was pretty easy on the eyes for a young lad

Buffy is gettin her batteries!

Richard, an episode idea could be about the key components of a electric conversion business. What skills sets, machinery, tools, and administration/ logistics are required. I, with very little technical skill and zero qualifications have a idea of electric conversion of old tractors for lifestylers or small holders I think you call them over there. Converting old classic small tractors, ditching the PTO for all electric implements and tractor becomes power station for every tool on the farm. All while looking very cool in your 1950's Massy Ferguson. Converting old machinery to electric would be sooooo cool! This episode was very interesting too btw.

@ElectricClassicCars

Жыл бұрын

Great idea. 👍

As they say, 'There's no substitute for hard work'. Thanks Richard. Nicely demonstrated and explained.

Need to pull a finger out Richard. It is now Feb and you need that car in a container and on a ship by First week of March to get it to USA ,then customs cleared and then to the track at Pikes. You will see congestion at the ports with some vessels waiting up to 7 days to berth, then delays in customs and offloading / unpack. Then you got to get it to Pike Peak ,. Road transport still a bit of an issue up Northern state of USA and dont underestimate the ice and snow delays . Winter in feb can cause havoc. Would not want you to miss the race.

Cool, I have been curious to see how this was done since you don’t get to see it on the tv show. Full focus for long periods. Once again a good informative video. 👍👍

@spudproductions7606

Жыл бұрын

Thanks 👍😀

@ElectricClassicCars

Жыл бұрын

That's why I like KZread so much, as we can get deep down and techie. 😁👍

Get down Shep! Thanks for making cells, modules and packs clearer to understand and the effort needed in wiring the packs up Richard, top vid again.

Crimp my ride... holy cow is that a job and half - If that was me, I think I would just turn my project into a handcar like they used on the railways back in the day -

Great video. Many thanks to you Richard & Tim. I've done a fair share of electric wiring, so I understand everything you've shown. I also understand the amount of time it takes to sort out, strip, crimp a terminal, snap into the connector, etc. over and over again. Plus checking your work along the way to make sure all is well. This type of work can be very monotonous and tiresome, so staying alert can be difficult when doing this for hours on end. Coffee helps considerably, but that of course leads to many trips to the lavatory. It'll be a long night. Personally, all was well until carpal tunnel issues made cutting & crimping incredibly difficult. *A while back a coworker and I were wiring up devices at a business we were working for. I was doing the high stuff while he stayed below working on the ground level. I kept dropping my tools because of my carpal tunnel issues, hitting my coworker several times on the head (he had a hard helmet on). After being pelted a few times he hollered up, it's a damn good thing we're not bricklayers! Once again, many thanks. Much appreciated. This was a very good video showing and explaining each step along the way (at least so far, many more steps to follow up on).

@spudproductions7606

Жыл бұрын

Thanks 👍😀

@ElectricClassicCars

Жыл бұрын

Those who know, know. 😉😁👍

Brilliant video. Great to see what is involved in conversions. Looking forward to the next episode.

Great video! 👏👏👏 No wonder why these conversions are not cheap 😅😅

Thanks for the primer! WAY back, I used to build model airplane battery packs from Milwaukee power tool batteries. About the time thermistors became a part of the dance, cheap batteries from China flooded the market... And I could no longer afford my own labor! I had been machining parts for, building, and winding my own motors too. It was so nice to set a motor up for the exact power, kV, and torque required by a given model... But, again, I couldn't afford my own labor! There was a brief time that I was thinking of using GM Electromotive cooling fan rotor laminations as stator cores to build a 20kW out-runner motor (with liquid cooling) for a light, enclosed, reverse trike. Life kind've got in the way, though. Edited to add: GM Electromotive Division is the part of General Motors (Chevrolet, Buick, Cadillac, etc.) that builds diesel-electric railroad locomotives. There is a local motor repair shop that rebuilds several different electric motors used in those locomotives. I found that, if I was properly polite, I could lay hands on some silicon steel laminations that make up the cores for any motors they work on. I was thinking of building a very large brushless outrunner model plane motor using a, roughly, 300mm diameter rotor lamination as a stator, with 50mm X 100mm X 25mm Neodymium-Iron-Boron permanent magnets attached to the rotating flux ring. Final drive would be via motorcycle shaft drive to the single rear wheel...using, say, a Honda Goldwing swingarm. My model motors tested above 90% efficient from battery to propeller input shaft...no reason this wouldn't be in the same range.

Good job for an apprentice, make the wire lengths that is.

Thank You for wiring the pack for us. I can see now to get battery life longevity, you need MORE than just plopping batteries in and go. Also, Balanced batteries. I saw that term on my charger for Radio control lithium batteries. Never new what it ment, till now. THANK YOU 🙏

@spudproductions7606

Жыл бұрын

Welcome 😀👍

Great video love seeing the tech behind the builds! I work for a company in the Netherlands building electric boats, mainly the tourist canal boats in Amsterdam, 2x 40kw motors, 144v, 1200Ah system, that's then 7 sets of 11 12v batteries, so 77 batteries! Luckily we use a Canbus system with m12 connectors to run the BMS instead of wiring every cell individually 😅

@ElectricClassicCars

11 ай бұрын

Very cool!

Another insane sleeper project, Richard? I am enjoying my lunch as I watch this. Very interesting!!!

@ElectricClassicCars

Жыл бұрын

Glad you enjoyed it

Brilliant episode! Please make more like this

@spudproductions7606

Жыл бұрын

Thanks 👍😀

Awesome info as always Moggy. I wish you actually showed the balancing, that sounds really interesting actually, even though your explanation was spot on. Also i really need to figure out where you get all the tools for the different plugs, because in my beetle i had a few pins come disconnected and it’s nearly impossible to fix with out the tools to de pin and pin back up. Anywho, keep this up, so fantastic to see how you are actually building it. Thanx for you time. TZ

All that talk of crimping made me want to watch some Mighty Boosh

A lot more respect for all the work that goes into the process of getting those batteries ready. 🙂 Thanks.. Jim Bell (Australia) Looking forward to being able to tow my 3 1/2 ton caravan for 350 to 400 km with an EV :-)

Your tech videos are gold!

@spudproductions7606

Жыл бұрын

Glad you like them. 👍😀

Another step in this interesting project.

Nice one moggy 🙏

Great vid,very interesting!

Super informative thanks!

Love that Dilithium kit 👍

396 wires, easy peasy. Telecommunication copper cables can have 8000. and when joining, they have to be matched correctly. Easier now with fibre optic cables, they may only have 288 glass fibres, but joining them is a wee bit harder. Still a cool video. I find this stuff interesting. be nice to see that beast going.

@spudproductions7606

Жыл бұрын

Thanks 👍😀

@ElectricClassicCars

Жыл бұрын

So.... Looks like we should employ ex- BT engineers then? 😂😆😉👍

It's much more fun with a Nissan Leaf BMS. One Neg and 96 positives with the last ones at almost 400V so they give you a nice wee bite when you get it wrong. 😋

A very long job but the end product will be 👌

Ah the memories. My first job was at a cable harness manufacturer. We actually had auto crimping machines with 10,000 crimp reels on them. You would insert the wire, push the pedal and Ba Bomp, the crimp was put on. Of course they had finger guards in front so you didn't accidentally crimp your fingers. I don't know if a autocrimper will work, since your harnesses seem to be partially installed as you manufacture them. We had all the wires pre cut to length and made the entire harness before inserting all the contacts into plugs. Have you ever put together a wire harness board? Really helps with laying out the wires and applying all the cable ties. Do you use hot tweezers to strip your wires? I spent numerous hours stripping the insulation off of wires with a Meisei HOTweezer. Does a great job and never breaks strands. I also noticed that all the wires are white with individual numbers. Is that necessary? It seems to me that having a rainbow ribbon cable of the proper gauge with 12 wires on it would work much easier. Then you just plug the proper color into each pin. I worked in QA for a couple of years, so I tested a LOT of harnesses. If you have a standardized battery configuration making a harness diagram and pre-cutting and assembling the harness might be a time saving and cost effective measure. Of course, if you aren't building hundreds or even thousands a week then maybe not necessary. I like the little tester that you hooked up. We had similar testing equipment. Cirris made testing units that you could plug all your connectors into and then check for miswiring or shorts. I would test hundreds of cables daily by plugging and unplugging all those connectors 🥴 I'm currently unemployed and I would love to work at your shop. Bit of a commute though, I live in Oregon USA 😩 You don't have plans to expand do you? I know our little electric car manufacturer here in Eugene, Arcimoto (maker of the FUV - Fun Utility Vehicle), just filed for bankruptcy so there is a shop here if interested. I was actually hoping to get on there, and now this. I can dream.

@petervarley3078

Жыл бұрын

"I also noticed that all the wires are white with individual numbers. Is that necessary? It seems to me that having a rainbow ribbon cable of the proper gauge with 12 wires on it would work much easier. Then you just plug the proper color into each pin." I was thinking exactly the same thing when I saw that section of the video. All white makes it harder to see if there is anything wrong.

That was an awesome episode thank you so much for sharing

@spudproductions7606

Жыл бұрын

Welcome 👍😀

@ElectricClassicCars

Жыл бұрын

Our pleasure!

Great in depth video. Definitely crimp my ride!

@spudproductions7606

Жыл бұрын

Thanks 👍😀 we like to do a mix of techie and fun episodes.

@ElectricClassicCars

Жыл бұрын

Crimp my ride. 😆😂🤣👍

It's exactly like this. And Richard, you've left out the double checking and triple checking, before connecting the plug into the BMS. I hope this goes a long way towards explaining to people why getting a professional outfit to convert a combustion car to electric is going to cost you a good bit of money. There simply is an awful lot of work in it.

@spudproductions7606

Жыл бұрын

Well said 👍😀

seems like a gap in the market for battery modules with built in (or at least compatible plug and play modules available) with multi pin connectors ready to go. The task of battery pack wiring and construction using ad hoc material in this way is one of the reasons my series 3 landrover still has an ICE! would much prefer an of the shelf battery pack. Well a man can dream, keep up the good work while I keep saving my pennies.

Great episode. This is the stuff I personally find really interesting, as it applies not just to cars. I'm curious how you will flush bubbles out of the cold plates!

A quick way of multiplying double digits easy is 16x6 = 10*6+6*6 so 60+36=96

Magnifico !

The first rule of BMS club is we don't talk about BMS club

When converting vehicles to EV, it’s important that people are able to view this labor intensive process. Goes a long way to aid in explain why these customvehicles cost more than average. Now, I’m not taking into account available kits for home mechanic. But, this video is excellent. ECC fantastic work!

@ElectricClassicCars

Жыл бұрын

Thanks. 👍

I wonder at what point it would make sense to put a small microcontroller at each cell that measures voltage and temp and then reports data over a powered 2-wire bus (like 1-Wire) to the BMS computer. It would simplify wiring and modularity I think, but also introduces more electronics. It's hard to beat the reliability of a good wire 🤣

@davidef4162

Жыл бұрын

I wanted to post the same comment

@davidrumsey3180

Жыл бұрын

Reporting cell voltage is only part of the job... The BMS can bring the cells into balance by manipulating the charge to each individual cell.. to achieve that, each cell has to be wired to the BMS individually.

Say it with us man, we will update you on the teslarossas post haste. 😁 Also you could make a dream of mine come true. By saying that countach shell in the back will one day be an awd ev monster. 👍🏻 Also when this is done bring it to tracks all over. I'd call it the beetl-E 😎

@ElectricClassicCars

Жыл бұрын

Countach..... One day. 😆😉⚡👍

Thank you

@ElectricClassicCars

Жыл бұрын

You're welcome

I thought blue peter was winter for a male nudist Love your work 👍

I am curious to see how you pack those batteries into the battery boxes. I assume that the design will have a slightly larger volume than the battery pack. Do you leave the space between the batteries and the walls of the box and it would not matter about vibration or movement (albeit very small). Or do you use a packing spacer. I also assume that expanding foam in a plastic bag will not be able to handle heated batteries? Anyway, keep up your entertaining videos.

Hello Richard, do you use any form of conductive paste between the battery modules and the cooling plate?(like they use in computers)

@Krishna-Govender

Жыл бұрын

I doubt that it needs thermal paste. Temperature changes in the battery don't happen as quickly as in computer CPU's. CPU's are also more fragile and the transistors will literally cook in a matter of seconds if the temperature isn't carefully controlled.

Very informative !! Can you show how each pack is connected to the main power terminals, and what type of cable and crimps etc you use 😀 and does each pack have a fuse or breaker ??

@ElectricClassicCars

Жыл бұрын

Good ideas for a future episode. 👍

I can see a time in the future when DIY motorists or at any rate back-street garages will have a go at battery pack repair. What could possible go wrong?

I don't get why LG doesn't sell modules with an integrated BMS satellite. That would be an instant upsell to their own BMS master and I think everyone would be glad to use that for the convenience, am i wrong?

@kschleic9053

Жыл бұрын

Afaik LG doesn't sell these modules directly to anyone except OEMs, and they are designed to connect to a BMS satellite, but the satellite is designed by the OEM. All of LGs supply is being absorbed by OEMs, so there isn't any business case for selling them to individuals...

@ianmangham4570

Жыл бұрын

Would you put the satellite 🛰 in a geo stationary orbit? 🤣

If I’m understanding correctly, the three battery packs will be in parallel. Is there any balancing between the packs then? Or other considerations to keep the three BMSs doing their jobs independently?

@ElectricClassicCars

Жыл бұрын

The 3 packs will balance themselves to each other as they're in parallel. 👍

I may have missed some video where you explain this (albeit I think I've seen all of your fantastic uploads), but can you explain why you are not using Tesla batteries, totally connected, with what most experts think is the best BMS, temperature handling and so on, there is? Also, I hope you will find the time to answer a previous question I made about converting my -77 M-B 450 SL... 🙂

@ElectricClassicCars

Жыл бұрын

A lot of conversions use Tesla batteries. 👍

Very interesting video, really enjoyed it. Do you also need to balance the 3 battery packs together once their individual batteries are balanced within the pack?

@ElectricClassicCars

Жыл бұрын

All modules will be balanced together. Then, once the 3 packs are mounted in the car and because they're in parallel they'll balance themselves.

Great episode. You mention in the video that the battery operating range is 3.3v to 4.2v. I believe those are voltages at rest. Any view on the minimum voltage that the pack can tolerate while driving for short periods of time. For my project, a Karmen Ghia (inspired by your season 1 episode 1), I am trying to set some warning lights if the voltage goes too low. I have a hill I need to climb near my house and that really lowers the voltage when the battery pack is at 3.7v … but battery still has 30% charge at rest. I currently have low voltage light set so that alarm goes off if voltage goes below and stays below 3.1v for 5 seconds. Do you think I am damaging my Tesla batteries if I pull back on power when light comes on? Setting the warning at a higher voltage impacts my total range. Thanks for any insight.

@ElectricClassicCars

Жыл бұрын

If you can set the motor to derate at lower voltages. Seeing the cells dip below 3v for 10 seconds or so under load is ok, but don't let them sag lower than 2.7v at any time if possible.

@marcelovandekamp1737

Жыл бұрын

Thanks for the advice. Yes derating the power is my goal.

@ZOD268

Жыл бұрын

@@ElectricClassicCars, 2.5V is the lower limit. But you all know that 🙂 Usually the hard limit would be set at 2.55V. Dipping below 2.5V does not immediately mean you would scrap the battery. Cycle life will be degraded (how much - a lot of variables influence). Most of builds like this ones and conversions, cycle life is not important. Having lower limit to 3.X V will significantly reduce the available energy. And yes, I know EV West stated on their website lower limit of 3.3V on cell level. Wonder why 🙂

I watched a video on ( The inja ) he did a load of batteries on an EV on a Ducati an it was great

Big letters 🙂

I'm assuming that if a cell is out of range of hundredths of a volt that the entire module would need to be balanced, or is it more necessary to actually try to change the cell of the module? You only went into how the exception of a module is handled.

I was wondering if you ever thought of converting a Tractor.

Do you do any charge/discharge testing before it goes in the vehicle? Seems like it would be good to catch a bad pack or cell before moving all that weight. Or have they generally been very reliable from the start?

@ElectricClassicCars

Жыл бұрын

Yes. All modules, new and secondhand, get tested before they're accepted into stock. 👍

Hi Guys, You've done it again, I'm writing another new version to my plan for the Spitfire. I was looking at the Orion 2 bms, but that Thunderstruck system looks lighter and more flexible for split packs. Are they your go to BMS?

@ElectricClassicCars

Жыл бұрын

Yep, we stopped using Orion 5 years ago and only use Dilithium now. 👍

@jamesfromwellington

Жыл бұрын

@@ElectricClassicCars have you used them to control type 2 and the ZeroEV CCS charge systems?

Where do you get the crimpers and terminals from? Could be a handy addition to my toolbox

Hello. I find your channel very intresting and following it. i was just wondering is the battery housing welded mild steel plate and if so? could it also be made from aluminium or is there a reason not to. thanks Ed

@ElectricClassicCars

Жыл бұрын

Yep, we make some battery boxes in aluminium. 👍

Can you please explain in more detail the balancing process? Is it done by connecting the module terminals in parallel?

@alpenfoxvideo7255

Жыл бұрын

if you connected them in parallel the circuit would essentially be a short and generate enough current/heat to burn the wires or even the cells. With the smaller Li-Po cells we had a balancer which either charged the low cells or slowly discharged the high cells. The only way to YOLO it connecting them in parallel is to have big resistors between each cell to slow down the current flow.

Great Video. I have a question! You said that if a module had a cell at 3.09 V and another at 3.75 V, that would be bad. What, if anything, would the BMS do about that? Would it mean the module couldn't be used? Or would the BMS somehow balance the cells?

@ElectricClassicCars

Жыл бұрын

It would try to bring the higher cell down, but it would take a long long time. They're designed to balance cells that are slightly imbalanced.

when using multiple battery boxes do you fit a fuse or contactor ( or both ) to each battery box ?

Ok, thanks! So, all the cell within a module need to have a voltage near enough the same, else that is not good... Difference between the voltages of the various modules can be evened out via (overnight) balancing.... So can the voltages within a module be balanced? Or is a module faulty if there is a voltage imbalance within a module? On other words, can a module be 'repaired' if there is a voltage imbalance, of is it a return under warranty?

what brand of BMS are you using?

How many cells in a pattery pack have to fail before that battery pack fails and shuts down the vehicle. How reliable are the little batterys cells in the pack.

@ElectricClassicCars

Жыл бұрын

It completely depends on the design of the battery modules i.e. how many cells are parallel. A typical Tesla model s p100 module 86 cells in parallel. You'd need quite a few of those to completely fail before it became too much of an issue.

How long does it typically take to complete a single 6 module pack?

Hi Richard, a question, Have you looked at using active balancers? There are some higher current active balancers with BMS's coming out now, wondering what your thoughts are on these? It seems that these would be a better option as they do not burn off excess energy but rather shift the energy from one cell to the next.

@ElectricClassicCars

5 ай бұрын

Seem like a good idea.

@GapRecordingsNamibia

5 ай бұрын

@@ElectricClassicCars I have not yet seen any EV BMS's with this capability yet, only on home storage BMS's.....

Hello, question for you, why steel battery boxes vs aluminum? Is it a strength or fire resistance advantage? Or just preference for the fabricators? Thanks!

@ElectricClassicCars

Жыл бұрын

We do both. It's just a question of whether the conversion is weight sensitive and whether the battery box requires the structural strength in certain places. 👍

What BMS system are you using ?

@ElectricClassicCars

Жыл бұрын

Dilithium. 👍

Are there multiplexed battery management systems?

What brand BMS are using here and is there one brand over the other do you like. If you are using the Model S batteries there is only 6 sensors plus two temp sensors so if you use 5 or 6 batteries 36 + 12 = 48 wires for a BMS? Thanks very much, nice explanations.

16x6 I go 16x10=160/2=80+16=96

12v for the controllers, from a separate 12v battery?

What a mess. The BMS harness needs to be manufactured with ribbon cable, and since the even/odd geometry is no surprise, 2-row connectors. Then, a visual inspection would be 95% assuring. I would still test and test and test until satisfied.

I’ve now watched this video 5 times. Questions questions questions. I am helping my friend build a dual Tesla motor Exocet. We are picking up 18 Pacifica 16s modules Friday. We haven’t picked a bms yet. A company on the west coast of the states sells parallel boards for the Pacifica modules and they suggest wiring 3p with the boards 6s. This basically saves money by not needing an MCU and 3 satellites per pack. Not considering the money saved. Do you see any advantage or disadvantage to using the parallel boards? Is it better the way you wired your batteries up?

@ElectricClassicCars

Ай бұрын

Running batteries in parallel is fine but I wouldn’t wire up cell taps in parallel. Always try to wire cell taps up individually, even if the battery modules themselves are in parallel.

To clarify: When a British person says "the off side", they mean the same as an American saying "the passenger side" or a sailor saying "the starboard side". It just means RIGHT. If they are confronted with cars with the steering wheel on a side they are not used to, they will say "right" and "left". Case in point: This car has the steering wheel in the MIDDLE and is not meant to drive on any road at all,, and I will still bet a sixpence he means RIGHT when he says "off side". 😎

@robinguitar

Жыл бұрын

No. Off side in a car is the side to the road centre. The side to the kerb is the near side. Right or left hand drive, the rule is the same .

@geirmyrvagnes8718

Жыл бұрын

@@robinguitar Even if that was true, it wouldn't matter, since the rule is only used in countries where they drive on the left. And also it is not true. By your logic, how does a single-seater race car not meant for road use have an off side? It just wouldn't. And yet it does.

@geirmyrvagnes8718

Жыл бұрын

@@robinguitar If an Englishman took his own car on a holiday in France and curbed his near side front rim, would he get his off side front rim repaired when he got home? That is just silly. OK granted, it is England so it CAN be quite silly. :)

@-Lucky-Six-

Жыл бұрын

@@geirmyrvagnes8718 no, as a Brit i can confirm i would get the curbed wheel repaired and wouldnt have to explain which side it was on as it would be the damaged one :)

@spudproductions7606

Жыл бұрын

We are in Wales, so you get to drive on either side of the road 😂😂

Yes please, get Carol…….

What was the reason for not using Tesla battery modules on this project?

@ElectricClassicCars

Жыл бұрын

Space constraints. 👍

@ianmilne655

Жыл бұрын

@@ElectricClassicCars I did wonder they are fairly compact 👍

How many AH are each of the 16 Cell Packs ?

@ElectricClassicCars

Жыл бұрын

Each module is 2.6kWh, each pack is 15.6kWh. 😆

Hello mate she is coming along

How many kwh will it have?

@ElectricClassicCars

Жыл бұрын

46kWh. 👍

How many AmpHours do you have on that 96S (400V Li-Ion) system?

No crumple zone for side impact?

@CrazedCrittic

Жыл бұрын

On a drag strip? :)

@72mardy

Жыл бұрын

@@CrazedCrittic it's a circuit racing vehicle

Only one comment "Down Shep" 🐶🐶🐶🐶🐶🐶🐶

@ElectricClassicCars

Жыл бұрын

I remember watching that. 😆😉👍

First commenter!

@sydsnott5042

Жыл бұрын

First sad git more like. Make a proper comment and not a childish one.

@matthewdilks2677

Жыл бұрын

@@sydsnott5042 does making fun of people fulfil your empty life

@LosZonga

Жыл бұрын

@@sydsnott5042 So you hate kids? What else? Comments? What else? Humor? What else? Yourself?

Why are you connecting 12 wires per pack if there are 16 cells in the pack?

@spudproductions7606

Жыл бұрын

126 wires per pack

@mattdavies3023

Жыл бұрын

@@spudproductions7606 👍 I mean to the BMS. Why is it not one wire taking a reading from each of the 16 cells in a pack?

@ElectricClassicCars

Жыл бұрын

It is, but we just wire them up in batches of 12 at a time.

😑🥱

@sydsnott5042

Жыл бұрын

🤣🤣🤣🤣

Rachel Riley is better.

@spudproductions7606

Жыл бұрын

She wasn’t available either 👍😀

@ElectricClassicCars

Жыл бұрын

Can't argue with that. 😉👍