Electric car conversion battery pack build part 1, Tesla B Class modules 18650 cells

Part 1 - 36kw EV battery pack build using the newer version of Smart car Tesla battery modules. This is one of the simplest ways to building a safe and secure battery box using tools that most people will have at their disposal. We normally build every battery box using aluminium but we thought would take this opportunity to show a more DIY friendly and cost effective approach. 18650 cells within each module.
Required tools - Drill, Grinder/ cutter , Mig Welder, tap set, engineering angle and tape measure.
Required materials - 25x25x3mm box section
Metal box shown in video can be found here:
www.schneider-...
70mm2 HV cable can be brought here:
zero-ev.co.uk/...
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[@life_on_cars]

Is the only way to get these parts from getting hold of crashed Tesla’s? Fascinating projects. I guess guys like you are the future of EV tuners! Keep up the good work can’t wait to see the Boxster run

[@Hazell_Nutz]

Tunna’s Auto Workshop yes currently but we also have some new battery’s under testing

[@joshuavincent7884]

Awesome...thanks for sharing. Much more practical volume for use in ev projects...36kwh looking dense in that cube configuration

[@reviewcrewforyou]

This looks promising for my 987 Cayman conversion. Nice work

[@Hazell_Nutz]

aDIYguy let us know as have a second pack that we could build for you. 50x48x98cm for the main box plus the small contactor box.

[@reviewcrewforyou]

@@Hazell_Nutz Right now I'm trying to find a crashed model 3 and use the motor or motor(s) from that and was thinking two volt battery setups but this may be better?

[@Hazell_Nutz]

aDIYguy currently no one as the model 3 motors working. So maybe look for a model s or x. We are about to start hacking the model 3 system very soon. I would avoid volt the good for discharge but very bulky. Maybe get a bolt pack.

[@reviewcrewforyou]

@@Hazell_Nutz I want to use the car mostly on road course so I was hoping the better cooling of the model 3 stuff would allow more laps than model s/x motors? I think someone has already hacked the 3 just not diy level yet?

[@Hazell_Nutz]

aDIYguy you can modify the coolant system on the large drive units I have a mod for it that splits the motor and inverter onto different loops. Then with the small units there already split inverter/motor so you could run them on separate cooking loops. I have not seen any model 3 systems yet so please share if you have mound one.

[@divinegt8605]

I Really need this cos i also want to build an elecyrIc Car

[@KennyGillis]

Hello Zero EV, thank you for your videos, they are excellent. I'm curious if this is the same box you put into the Boxster? I am hoping to use the same B-Class batteries and this box design for a 996 911. Do you have any idea if it would fit in the back where the engine originally was located. I know you said in another video that these modules are 90cm long. I will be doing some measuring today. Thank you!

[@Hazell_Nutz]

Yes this is the pack we fitted into the Boxster. It’s not high performance so will only give you about 150hp peak

[@KennyGillis]

@@Hazell_Nutz Oh okay, I was planning to run the Model 3 Rear Drive Unit with it. Sounds like it won't be enough. Do you recommend another battery pack option? I would like to stay less than 40kwh for weight reasons if possible. Thank you!

[@Hazell_Nutz]

We have the model 3 drive units coming out end of this year and actually will show them on the volt this Sunday. You could do 35kWh pack made of 16 x CALB 2p6s modules. We sell them on our website and keep them in stock along with all the busbars and cooling plates.

[@KennyGillis]

@@Hazell_Nutz Okay great! I'm guessing the B-Class battery won't work due to the model 3 RDU current requirements? Thank you for answering my questions and for your videos. They have been so helpful in giving me the confidence to take on this dream project build!

[@Hazell_Nutz]

We are actually going to be fitting a new set of modules into the Boxster as the current ones are already at 70% capacity

[@TairnKA]

As expected, what's the average range of a conversion? I'm guessing the TESLA fast charge system isn't available for converted vehicles (In a video of a rebuilt TESLA model 3 couldn't use one)?

[@Hazell_Nutz]

About 100 miles

[@TairnKA]

Every month I drive 80 miles (round trip) to visit my sister, then do chores (store, gas, lunch, etc...) so "about" 100 miles wouldn't work, between 150 to 200 miles (300 preferably) would be good. ;-) I was thinking of a 1966 Corvair convertible.

[@bumblebimmer]

Oil ...on the drill bit .

[@MrLikerBiker]

Did the battery modules come with their own Formex covers or did you design your own?

[@Hazell_Nutz]

MrLikerBiker Hi, They come as seen in this video. We have also just designed a new plug and play replacement bms brake out board

[@gryzman]

are these tesla modules ?

[@Hazell_Nutz]

Greg Jaskiewicz they are made by Tesla but where sold to Mercedes zero-ev.co.uk/product-category/battery-modules/