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Dala's EVNX buildthread (1991 Nissan NX)
(03-13-2018, 10:10 AM)zag2me Wrote: So what type of motor are you considering for this project?

DC, 20-30kW range. Still kinda on the fence.

The additional Opus'es showed up, first thing to do is to add 120mm fans to them
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And here they are put into 24/7 operation. Now I can dig into the backlog of cells with triple the speed!
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Back to chassiprep. I modified the front support beam, by chopping off the radiator mounts to save weight. After that I covered it all up with Rostex. All that is rusty in this picture is the horns, I am unsure if I'm gonna install some newer ones or refurb the old ones.
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Let's tackle the ABS system. When I did the tierod ends, I noticed that the sensors crumbled into dust when you touched them. I highly doubt that this system was operational to begin with. Here's the pump, with the two outlets disconnected from the distribution block. This is a clever system, the brake cylinder has two outputs, each going to a front/rear combo, to maximize safety if one fails.
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Here I removed the pump, rerouted the pump inlets into the distribution block, bypassing everything. Now the pipes just need to be bent into a cleaner looking shape. The pump weighed 3kg! so it was def worthwile to remove it.
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And here's the area after prepping and painting.
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To be able to remove everything else related to ABS, we first need to remove the dash. Here we have full access to all remaining electrical connections. The ABS ECU sits in the lower right corner.
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ABS ECU. This was a heavy one too! Feels very satisfying to remove weight, it's really addictive Smile
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Remember the rusty fenders? I treated one of them, ground everything down to bare metal, zinced, rostex, ready for installation. 
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zag2me, jdeadman, Korishan And 1 others like this post

With the three testing stations running at full steam, I can now process a bit bigger amount of cells per week. It seems way more attainable now.
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But back to the garage. I picked up a few more suspension bits, two front sway-bar end links, two bushings for it and a discounted -70% CV joint! This will help when it's time to puzzle together a beefier axle setup.
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I started with dismantling the suspension. The knuckle/hub needs to be refreshed. Also look at the amount of corrosion where the brake line connects! Yikes. Brake fluid sure likes to eat paint...
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Here's the rusty knuckles in closeup. Sandblast time? Don't worry about the shocks, they are not going back on Smile
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With everything removed, I angle grind-ed down the wheel arch to bare metal. This took quite some time. After that I applied hammerite to seal it. At this time I noticed that the caliper glide bolts were totally rusted shut. I will need to source some new ones, maybe even new calipers.
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Now I could start with what I really wanted to replace. The sway-bar hardware. Looks like I caught them just before they turned into dust!
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The bar looked quite crusty, so I gave it a whirl with the angle grinder. Grinding round objects is not easy :/
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The bolts and bracket received the same treatment, now some zinc after cleaning them up.
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Finally more metal hammerite to seal the deal.
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Final assembly of it will have to wait ~10 days, I'll be off to Amsterdam Smile
Korishan, EGOksy, jdeadman And 1 others like this post
I am back from vacation Smile

Ran out of cells to test, started breaking down more laptop packs. I only have 21 packs left now, will have to go scouting for more in uncharted parts of the city.

I have also encountered a few cells with surface rust on the positive side. I instantly discard these, wouldn't want it to spread or cause more issues down the road. Rusty cells often look something like this (not my picture)
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I have also gotten tons of Sanyo "Heaters" as they are often referred as. They get this nickname since they tend to run hot when charging. I am monitoring these cells closely, some say that heating up is a normal process for cells that have sat for a long time, that the cells need to burn off some oxidation? or something, and the next charge is supposedly colder. I will for sure try this, since so many of them fall in the 2000-2200mAh range. Here's a progress pic of some high capacity cells.
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The known good cells, from another angle. A quick count netted me ~320 'A' batteries (2000-2700mAh), that will be used for the car. I also started piling up the 'B' batteries (1500-1999mAh) that will be used for the 24V offgrid upgrade in the summer. It ties heavily into the R&D for the EVNX, so I will just contaminate this thread with all the offgrid stuff when the time comes. Sorry Smile
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Also, if someone wants more regular updates, I have an Instagram account, @dalathegreat , where you can get more background pics from my previous projects

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Korishan likes this post
Is Hammerite pretty much the same as POR15?
Sanyo'c can be great cells. If they Heat I put them aside for other projects but the non heaters are great.
EGOksy likes this post
(04-04-2018, 08:02 PM)jdeadman Wrote: Sanyo'c can be great cells.  If they Heat I put them aside for other projects but the non heaters are great.
Yeah, I mark them with 'H' if they are hot, these are the ones I will cycle for a while before deciding if they are A grade or B grade. Having fond memories of Sanyo NiMH in the past, I really like Sanyo as a brand. My only dislike with their 18650's is the awful red wrapper, it doesn't feel like quality. Not that it really matters, they will be quite tucked away Smile

(04-04-2018, 08:00 PM)mike Wrote: Is Hammerite pretty much the same as POR15?

Not really. POR15 is heavier, harder to apply, but more forgiving when it comes to rust treatment. With Hammerite, you need to really get the area rust free before applying it. Hammerite is cheaper, so I will continue to use it, since this project will require loads of it :Smile I will also apply more stuff on top of some areas, stonechip protection etc. Both POR15/Hammerite would work excellently for these kinds of projects though Smile
Good stuff! See if you can snag an electric power steering pump from a junkyard. I believe Prius' came with them. Just go to some local yards and ask if they've got any electric ones.
(04-04-2018, 08:02 PM)jdeadman Wrote: Sanyo'c can be great cells.  If they Heat I put them aside for other projects but the non heaters are great.

I like when i get a red one SANYO  showing  big numbers Smile  makes me happy.. because lots of them goes back to recycling Sad 
love the ZT ,ZTA and FM that  goes over 2400mAh Big Grin

(04-11-2018, 05:36 PM)goeielewe Wrote: Good stuff! See if you can snag an electric power steering pump from a junkyard. I believe Prius' came with them. Just go to some local yards and ask if they've got any electric ones.

yes  they do have that :Smile  also AC unit may be handy .. this is also electric ... because mine 2011 Prius runs AC when ICE(internal combustion engine) is off. Don't know for sure .. but i think i read somewhere that ac has a heater also ..

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