Austin Allegro EV conversion: installing the electric motor

The Nissan Leaf electric motor has been installed at long last!
Special thanks must go to Bob for his incredible engineering and his valuable time. He managed to make a cumbersome Nissan electric motor stack fit into the tight confines of my Austin Allegro and somehow he even made it look easy! Words cannot describe my gratitude.
I'd also like to thank Adam for donating his time and energy to help me remove the combustion engine from the Austin Allegro. Couldn't have done it without your help! Plus, I'd like to also thank fellow EV converter and walking library of EV knowledge Nick Smith for letting me borrow his racing scales and for letting me pick his brains about New Zealand's electric car conversion rules.
My sincerest thanks must also go to those people who donated their time or resources to help get this project off the ground. Your efforts are always in my mind and I'm so grateful.
Now that the Nissan Leaf electric motor has been installed, the next step is to transport the car to Auckland to have custom-made driveshafts fabricated to go between the Leaf's reduction gearbox and the Austin Allegro's CV joints. Then I'll transport the car back home and remove the motor and subframe (see how easily it all comes out?!) then paint everything nicely. After that, it's time for components, followed by the big question: what size battery pack should I put in it?
Things are gonna speed up now so stay tuned!
And if you're having trouble sleeping and would like to watch the EV reviews I make for a living, click here at your peril: • ecoTEC EV Reviews
Contents:
0:00 - Introduction
3:00 - Removing the LEAF wheel hubs
4:52 - Removing the LEAF motor
7:45 - The Allegro's final combustion moment
9:05 - Allegro parts removal
11:20 - Home refueling
13:03 - Allegro engine removal
15:50 - De-greasing the Allegro
16:26 - Hauling the LEAF away
17:52 - Rust repair & painting
20:04 - Will the LEAF motor fit in the Allegro?
22:06 - Transporting the Allegro
24:06 - Allegro in the workshop
25:47 - Engine mount work begins
30:35 - Creating reinforcement plates
32:17 - Mystery trucklet
33:07 - Motor mount brackets
34:01 - Subframe mount creation
36:05 - Bob creates the subframe
37:48 - Installing the subframe
41:05 - Installing the LEAF motor
43:15 - Will the bonnet close?
44:06 - Weighing the car
44:58 - THE MOTOR'S INSTALLED!

[@stevenharpervw]

Nothing to do with the video but I just want to tell you. Thank you, in a previous video you said you left your ex ex wives and feel much better and you started a new life. I was fairy bumbed out at the same time because my gf left me. But your video/ comments helped me, made me more positive and felt better . I’ve since met a really lovely girl . So thank you

[@KiwiEVadventures]

That's really good to hear. Time heals all wounds, but some wounds take more time than others. I'm really glad you're improving.

[@memorialgardens1664]

@@KiwiEVadventures so true 🧠💪🤝

[@jaja0374]

amazing work

[@evjpgarage4976]

This guy GAV is an inspiration

[@stevenharpervw]

Btw I’m from Ireland, so on the other side of the world your helping people too

[@KanedaBomber]

Your welder friend with the workshop is so charismatic

[@craigknight2764]

As others have said, your perseverance and positivity are infectious! Loving seeing this project coming together. One day, i may get to do the same 🤞

[@danburt1979]

It's coming along so nicely, and seeing the motor, subframe, and mounts fit in perfectly was so satisfying to watch!

[@lancpudn]

So happy to see this latest Allegro electric build project video. Bob is certainly a talented chap & hats off to him for that awesome subframe, fabrication & welding job. Great work from both of you.

[@evjpgarage4976]

Gav, brother.... you are such of an inspiration... Since your very first video... Your positivity.... is amazing!!!! Well done again !!! I really can't wait to the next video! I wish you all the very best ! Thank you for the video ! Thank you for the piece of happiness watching you... surviving 2 electric cars... 2 wives... and now... on the 3rd electric car.... probably soon 3rd wife !!! I can't wait to the next video !!!

[@KiwiEVadventures]

You just put a big smile on my face. Thanks mate. You're a good human.

[@headwerkn]

Great to finally see the project coming along! That new subframe was some very tidy engineering work - and yeah, probably stronger than the rest of the car 😂

[@barryvica]

Fantastic job! I’ve been looking forward to this video for so long. I’m really thankful that you didn’t give in to the algorithm and release a series of 20 videos that that only show tiny bits of progress like most content generators. Clearly a lot of effort went in to this build and to making the video. It’s much appreciated! I can’t wait to see the next one

[@KiwiEVadventures]

Thanks mate. These videos aren't monetised and I made no profit at all from them. They're created purely to entertain people and share my joy. I don't think anyone does that anymore.

[@hakansjorling1340]

@@KiwiEVadventures But why not monetising these videos?? You seem to need more funding, and the project is fantastic _and_ entertaining. How can we support you? 🥰

[@peterburt2905]

0:26 that socket set...man, that's a beauty ;-)

[@lyledal]

Been eagerly awaiting this next installment! Fantastic! Also, Bob is awesome!

[@markwessels4069]

So glad you are finally making progress. Great work

[@Ruudi05]

You found an amazing helper or was it other way around. I really like that you keep the Nissan drivetrain with it's original reduction gear that way it's the most efficient drive.

[@bobjetson]

We went to grab the same potato, and it took off from there

[@JoMangee]

So great to see the journey!

[@B49337]

Seriously awesome videos. Started watching the first one and just watched the entire set for the Allegro so far.

[@potter2702]

Awesome work by Bob & Adam, really does look good, can't wait for your next video.

[@wojciechhaase]

Well done! Been following you for years. Can't wait to see more

[@alan2804]

I laughed out loud at the public oil spill apology! Excellent and so bloody typical the world over.

[@nunorguedes]

Amazing Gav, the hard part is done, awesome nice work there with the motor, what an amazing conversion! Keep it up.

[@Superspaz1993]

man im happy to see it finally coming together! been following you for years now man, glad things are going well!

[@aatheus]

Man that motor looks perfect in there. Well done to you and Bob

[@SirHackaL0t.]

Good to see CAD being used. Cardboard Aided Design.

[@nimmoev7501]

Good progress lads, looks right at home in the engine bay, nice fab work 👍

[@MalcolmFaed]

Brilliant Gav. Work of art. Top work Bob!

[@MrKroolboy]

Amazing project and wish you all the best 👌

[@baitboy3191]

Made my day, seeing this video. Love seeing the progress

[@rosshunter9053]

What awesome progress. Hanging out for the next episode. Cheers

[@kafkaian]

Fantastic progress Gavin. You have some great friends. I particularly like the work you did with Bob to fabricate those engine mounts and brackets. Of course I have a special affinity with this model because (a) they were built a few miles down the road from me in Longbridge, (b) my mate had one in the 80's which we used to bomb around in and (c) my father would have repped from his job as an engineering troubleshooter for electrical parts (like light clusters) made by his firm Lucas's Awesome Ian, Birmingham, UK

[@bobjetson]

I have enjoyed this project sooo much! Bring on the next step! Edit: Thanks for all the awesome comments!

[@nathanielgritzman6961]

looking fantastic. loving the updates.

[@rospochin]

Nicely done - great to watch.

[@B49337]

Great videos. Just can't wait for the next one!

[@ClintonEtheridgea]

Congratulations mate, great work

[@Superspaz1993]

just finished it. thats awesome man! fits like a glove!

[@BenMitro]

Wow! You Gavin, have some very capable friends. The Nissan Allegro is born!

[@paultodd9301]

Love the use of CAD (Cardboard Aided Design). Good Luck for the rest of this project.

[@markboden2749]

Hi Gavin. At last, the wait for the electrolysed Allegro is over. Have been watching for progress on this project since you bought the car from that showroom. The Austin Allegro holds a very dear place in my heart as I worked in the Longbridge , Birmingham factory on the Allegro, the Mini and they’d just started running a new vehicle, The Austin Metro. In fact I as working there in 1977 aged 19. I more than likely even worked on this very same car. When in the video you removed that black plastic strip that held the carpets down onto the cill, I used to affix that strip. We were supplied with Stanley “Yankee” pump screwdrivers and one day we were given cordless electric drills made by a Makita. Brand new technology. It was quite a step up, I tell you. We used to do two weeks of days and two weeks of nights. I remember after working the Monday, Tuesday and Wednesday night I was so tired, I couldn’t keep my eyes open after the “dinner” break at 2 a.m. so somebody came up with an idea. “ I know, we’ll have a talent contest in the dinner hour. “ well it was a great way to invigorate everybody until home time. There were comedians, impressionists and when somebody did a skit as a ball-room dancer complete with scarlet silk sash, everybody pissed themselves laughing. It was brilliant. Happy days. And that was 40 years ago. The Austin car factory. It was a great place.

[@KamleshMallick]

Kiwi EV is the real Electric Vehicle Community Legend!

[@KiwiEVadventures]

LIES! SCANDALOUS LIES!

[@manierlinge7392]

Looks amazing looking forward to the next update.

[@corevamorebolmara1143]

Great to see you back Gav :)

[@jimcabezola3051]

A work of industrial art! I'll bet that drivetrain installation is better-engineered than factory. Very much looking forward to the next installment. Kia ora! (Or..."Aloha!" as we say out my way!)

[@KiwiEVadventures]

I'm seriously in awe of Bob's welding & fabricating abilities. I can barely make a cup of tea without setting things on fire.

[@jimcabezola3051]

@@KiwiEVadventures 😆🤣! Bob's certainly the one to have around when there're things to be welded! If he's not careful...he'll be inundated with MORE work like this. Like you, he'll be improving the world...one car at a time!

[@MikesTropicalTech]

Fantastic progress! I'm doing my 914 battery upgrade in parallel with you.

[@peterparsons7141]

You mechanic Bob is very skilled !

[@mr2981]

Bob is a godsend, well done!

[@gregfrance1548]

Big milestone! Well, done

[@MrQwebsoftware]

Love the series … keep going

[@joshfancher3244]

Man this is really awesome I love this video reminds me of the ole electric car you built years ago I have never heard of that car and couldn’t care less about evs at the time but I gotta say I was very interested in your videos and I really learned a lot from that built in pretty excited…to be honest I am very interested in evs as a diesel shop owner and it’s because of you man keep up the videos brother glad to see u again

[@jjsantala]

Nice, been waiting for this video!

[@hopeyoustumbleuponthis.8627]

Super to see it coming along. 😀

[@sergiosilva4016]

Very good my friend, amaizing 😊😊

[@ChromeFlakes]

Love this! So good to see that nasty fossil burner motor removed and this mega satisfying clean install. Total joyous viewing. I so want to do this myself. Cannot wait to see the battery install. Keep up the good work. Subscribed. 👍🏼

[@johnhornblow4347]

Top class engineering, bob makes it look so easy, but its not. Brilliant

[@Whereswally606]

I was sceptical you would have space but i see Bob is a man who can steer large boats into small habours. You've done excellent work both of you. Whats cool is youre using the aze0 stack so full v2g could be possible with this unlike the ze0 drivetrain. Eager to see more progress and i hope Bob gets some more interesting projects out of this. Excellent custom cardboard aided design there.

[@bobjetson]

Definitely more interesting things to come!

[@jp2en]

Bob is an awesome, very clever guy!

[@symondo74]

This is awesome. Its like the Mitsubishi tredia days all over but in HD. I hope you guys made a jig for that sub frame because once this goes viral the demand for allegro to leaf conversions will sky rocket.... oh wait.... no two allegros are the same. Scratch that. 😂 but in all honesty, great to see you back on the conversion project. Thought you might have been too owned by ecotricity. 😊 i think this also calls for an ecotricity plug with signup commission for allegro project for the win.👍

[@johncorlett3699]

allegroes, ahhhh, you could hear them rust in the showroom, austin 1100' s though, brilliant

[@GoneKayaking]

Cool project.. well done

[@chargeheadsuk]

Those Model s wheels are like mine on the model 3 💪. Good work by the way! 👍

[@youxkio]

I just can't wait to see the installation of the inverter and batteries.

[@bobjetson]

Inverter is in the motor stack as well as the charger.

[@youxkio]

Good strategy to save room.@@bobjetson

[@alexferrara4527]

How much of a legend is Bob!

[@bobjetson]

How much of a legend are you!

[@joeboonen7421]

Hope you lined up the drive shafts! Cool video.

[@df7816]

you guys are awesome dudes.

[@SirHackaL0t.]

Everyone needs a Bob in their life.

[@KCTalksEV]

You'll be surprised how often the Jeremy Clarkson approach works and for what applications, Great Video!

[@_autoverse]

This popped up in my recommended feed alongside another Allegro that’s had a drivetrain swap, your vid intrigued me more. You couldn’t have picked a more perfectly sized motor, Bob’s done well on the subframe too. +1 Subscriber

[@bobjetson]

Thanks

[@nicholashills6972]

Absolutely brilliant. My dad used to have one of these, I called it the tortoise, be interesting to see it run.

[@mmmhhh.]

I watched your ev diesel heater videos back in day, was watching saved videos and came across that diesel heater video again. How have you been doing. Hope all is good. Stay blessed man.

[@StanleyKubick1]

what a cool project. I'll sub for this. please add more content soon. cheers from Iceland

[@KiwiEVadventures]

Thanks mate. I'm getting close to finishing the next video!

[@fenrir7525]

Hell yeah, been waiting for this 👍👍

[@fenrir7525]

brilliant, can’t wait to see what comes next

[@mopedbanzi3275]

subbed, i get the lack of money vibe but you have a positive outlook and i think you'll smash it

[@Zarphag]

Man that's looking good.. As good as an allegro can anyhow! 😅

[@tonyzart6569]

Need to see it on the road as an EV: good stuff mate...

[@bibliotek42]

I am not given to young people's language, but this work is awesome, as in awe inspiring!

[@lipsee100]

Just something regarding that Allegro fuel tank,,,, Back in the middle 70s I was courting my former wife and my future father in law lent me his Allegro 1300 (only 3yrs old) to go for a day out to Bridlington. So I check the car over ,and looked under the backend (as you do!) I just lightly touched the fuel tank with my finger and the bottom fell out...Cost me 86 quid for a new one from the dealer,because said Angry future father needed it fixed to go to work the following monday.... That mech has done a really good belt and braces job with those mounts....

[@johntolmie1725]

This is smart. When you are done you will have a "how to" on repurposing a Leaf unit. That should be of interest to quite a few people. I see a few early Leaf's coming up at the auctions with tired batteries. So, at some point there will be a lot of Leaf units looking for a new home. There is a guy on youtube who put a leaf motor in a Honda CRX for drag racing. He built his own inverter, blew up a lot of expensive stuff getting that right. I think he was building an AWD version with two Leaf units. Leaf units are capable of a lot more power but are limited to preserve the battery I think. A quick search found a couple of options for getting the Nissan unit to run. Thunderstruck motors VCU and Resolve-EV's controller. I'm interested in what you plan to do here. Getting the Leaf charger/DCDC to work could be another challenge. Someone on youtube got the DC to DC to power up and charge the 12V by just applying the correct power to the correct pins on the car connection. Hacking the charger might be a bit more involved. Leaf motor and inverter are liquid cooled, Its a pity your wreck didn't come with those parts. Maybe Pick-a-part bits could fill in the blanks. Mangere yard has a Leaf, but its been there since June and is an earlier model. There is an electrically actuated parking pawl in the trans, apparently just needs 12v to disengage. Good luck and congrats on home ownership. PS., There is also ZombieVerter an open source VCU that will run a Leaf. Looking at the shop manuals for my Leaf it looks like the parking pawl is driven by a 3 phase star wound motor controlled directly by the VCU. Brakes, there are a couple of ways to go there, vacuum pump, or electrically assisted brakes. I believe some of the newer Honda's (2018 or newer) have electrically boosted brakes using the same Bosch booster as Tesla model 3. See kzbin.info/www/bejne/iYO9aYt6g99lrLc. I'm sure there are a lot of other cars that use electrically boosted brakes. Anything electric or partially electric such as a hybrid and then anything else with autonomous emergency braking. I was converting a Hyundai Accent when you were converting the Tredia. I still have a few bits, possibly the vacuum pump somewhere.

[@grant3226]

Glad be along for the journey again. Will we get a kiwi ev 2 dvd?😉

[@NewZeroland]

What tools do you need to do this? 1. Grinder 2. Plasma Cutter. Wow man.. what an amazing build. Bob's subframe is truly a masterpiece. Great job editing and narrating the video, too! I'm so excited to see what's next.

[@bobjetson]

I'll help you if you have anything that can be done remotely.

[@troyboy4345]

Great video, i am interested in how you will be integrating assistance for the brakes ? ... looking forward to the next video matey !

[@toyotaprius79]

Lumping a couple of Leaf cells in that drafty engine bay will do wonders!

[@brettbarnes7370]

Great video, I really enjoyed your effort with the conversion, looking forward to the next installment with the Allegro. I also liked your BYD Atto3 review and bought one myself. Fantastic little car. I am doing a $100 AUS challenge to see if I can make 5000 kms. So far half way there. I am using my solar house power, free shopping centre power and some holiday accomadation that will provide free power.

[@KiwiEVadventures]

That sounds really cool. Are you making a video or anything of your progress? Could be a fun watch! And congrats on the Atto 3. I see almost nothing but praise for them by their owners.

[@brettbarnes7370]

Hi Gavan, i did make a short video recently after watching your videos but mine is not as good as your USA video and others. This is the link to my Atto3 holiday. kzbin.info/www/bejne/f6Cxpn6jnbZnha8. Cheers Brett

[@blooddude]

I love this project! Thanks for sharing. You and Bob should do a few EV projects together, it's fun watching the chemistry. -Edit- you get and extra like for including Depeche 🙂

[@jaja0374]

Great pls keep sharing!

[@lavectech]

Great work, going to be sweet.

[@continental_drift]

Magic Bob!

[@rocketsciencedesign]

you should do a crowdfunding thing to help pay for this!

[@wilverine9086]

Fantastic work, nice in-depth presentation of some proper engineering or "backstreet mechanicking" as the late great Fred Dibnah would say. The pessimist in me is asking "Why didn't you make sure the motor runs before making the mounts?" though.

[@gwgplate2]

Fantastic.

[@JandusJ]

Liked and subscribed 🙂

[@patrickh7368]

EV unit fits in well… lot of hard work getting to that stage… Hope you don’t mind me mentioning, the rear mounts of the hand built subframe and it’s reinforcing etc, looks to be in the hole for the drive shafts, on camera anyway…? 🤞

[@sveip]

I'm eagerly waiting for the next update 🙂

[@KiwiEVadventures]

Me too! It should be before the end of March if the planets align.

[@sveip]

@@KiwiEVadventures great news! I'm grateful for whatever I get :-) Keep up the good work!

[@Paulman50]

Good to see the Kiwi EV channel up and running again, its been a few years since you did the Tredia. (I ued to own the Tredia before you). Are you still in Auckland .

[@4wheelsgood]

Amazing progress. I'm sure you've seen @thelatebrakeshow and Johnny Smiths Aggro project. Both good, but would prefer the Leaf powered one!

[@MrAnwarsmith]

Gav's E-leggro is way cooler than Jonny's Allegro conversion, and guild free! Recycling two cars into one emission-free beauty.

[@peterbradley4916]

brilliant!

[@scottwilliamson8322]

Enjoying your videos and like this build, just a note on the speedo, you can't get certified with a GPS speedo, they don't work in tunnels is the main reason I believe.

[@Greg29]

Wow was just thinking of you and wondering if you were still making videos, it's been a while!

[@miniguy1267]

I have been following your journey on LinkedIn and finally watched both videos. Potato 🥔 I like the subframe your mate made, neat, Potato 🥔 👌 Then I was so excited to see you finish the project in a supervideo, but alas, Potato 🥔 😢 I'm looking forward to the next Potato 🥔 😂 It Waa great to see the Leaf motor/reduction feature, controller/inverter and charger tower is about the same size as the A series motor/box. Potato 🥔 😅

[@caveweta]

Are you planning an off the shelf battery pack or building one yourself like the Jerry Rig everything Hummer?

[@bernardcharlesworth9860]

Good choice of car as hydroelastic can be adjusted

[@localreviewking134]

in the UK the All Aggro, er Austin Allegro was a loved and loathed family motor. I knew someone who had a Vanden Plas, he loved it. The Vanden Plas Austin Allegro was a more luxurious version of the standard Austin Allegro, produced by British Motor Corporation (BMC) from 1973 to 1976. It was not badged as an Allegro and was instead simply called the Austin Vanden Plas 1500. Did that model ever make it downunder? Great vid though, and not too must rust on this Austin!!

[@garylecarpentier9640]

I was wondering if you were going to update your project and here you are 😎, it’s a type of job I’ve been considering myself

[@onesoundJM]

Well this is well worth the wait, why did you not make it into more that One film? why have you not talked about how much it has coast you so far ? regards Joathan from Lower Hutt now in London

[@dutchbavarian]

Wow, really nice. How much did you pay for the Leaf and what is the story with the battery?