Let's Build A Cooling System For An EV Swap

An electric vehicle swap needs a thermal management system somewhat more complicated than just using a radiator. I, however, am just going to install a radiator for now. It will probably be fine.
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[@SuperfastMatt]

I've started adding post-credit teasers so that you can know what is coming up on the next video. I definitely didn't do it just so you will watch all the way to the end, increasing my favor with the algorithm gods. ALL HAIL THE ALGORITHM.

[@justchillinout2002]

All Hail

[@RoamingAdhocrat]

All Hail

[@mauricelaar9399]

All Hail

[@mikealbrecht3990]

Wassail!

[@5thearth]

Hail

[@del8798]

Great to see Super British Matt....he might be able to help you say aluminium correctly ;)

[@kkkkiaken]

Clarksons Dictionary: (AL-YOU-MIN-IUM) 🤣

[@LordPhobos6502]

"Too much cooling, is the correct amount of cooling." Love it. Also, if you don't have to hack up the radiator, you don't have to reseal it, etc etc... "less work, is the right amount of work."

[@PrebleStreetRecords]

"Too much cooling, is the correct amount of cooling." Addendum: "until you have icing".

[@etheroar6312]

@@PrebleStreetRecords Then you need cake.

[@SubTroppo]

No work, is the right amount of work. By watching this video I did that amount of work. (Procrastinate now!)

[@avanreijn]

0:37 A wise man told me this is actually called a heat exchanger.

[@RoamingAdhocrat]

that design's rejected

[@magnus.nasmark]

Yeah, I even took notes when he said that… Now I am all confused.

[@Papa-Bogey]

How wise could he be if he RUINED a JagWar ...

[@mikealbrecht3990]

I need a running count of how many times he puts the chrome kitty on the grill....

[@jimzucker]

take a shot

[@Mike_Costello]

"Kitty at my foot and I wanna touch it"............

[@vn1500g3]

To borrow a phrase - "Looks like Ray Charles welded it with his feet!" Outstanding! Thanks for sharing all your hard work.

[@craigleemehan]

I really like how you do not get hung up on perfectionism, "Let's try this now and we can do better later, if needed." So many projects get hung up perfecting the builder gets tired and quits. Not that I do that.

[@bobulele]

I'm intently watching this series as I plan my MGB EV conversion so I can do everything wrong but at least know a right way to do it. I'm going to use Lucas parts for the entire electrical system so I know it will smoke the tires. Probably the rest of the car too. I wonder what a good weld for a software developer looks like. Probably looks like panel bond. All hail the algorithm!!!

[@JohnHughesChampigny]

"I'm going to use Lucas parts for the entire electrical system" you mad lad.

[@bobulele]

@@JohnHughesChampigny lol possibly!

[@michaelhodgson3833]

..... Lucas ??, haven't heard of them since I was a car mechanic in the seventies, is that Elon Musk sobbing in the corner ?

[@Stu_2112]

Lucas......Prince of Darkness

[@michaelhodgson3833]

@@Stu_2112 , I'd forgotten that one, brilliant !

[@liveandletlive2894]

The monocle was a nice touch, but a glass of tea really would've completed it.

[@PaulLemars01]

Cup of tea. We drink cups of tea.

[@Tobias94b]

Could I have another cup of tea darling? *Spoken with a closed nose in a gayish tone* 😂

[@richardallen1629]

It's not tea without a saucer. 🛸

[@SubTroppo]

@@PaulLemars01 Mugs of tea. (ps should have added: call that coffee?!)

[@SubTroppo]

@@Tobias94b "Put the kettle on." spoken with a hint of menace.

[@DTMnoFear]

Hey Matt, idk about Tesla parts, but Inverter IGBT's generally have lower temperature ratings than motors (at least that was with my case with YASA motor and RMS inverter), and batteries are even more delicate, so I would route it Heat Exchanger -> Battery -> Inverter -> Motor. Agian, I'm not familiar with Tesla parts temperature specs, so this might not be applicable.

[@dentjoener]

As long as you don't have shit flow, the water temp will be pretty much equal in the entire loop. Maybe only a couple of degrees difference

[@brandondelgado4153]

I concur, Matt seems to have arranged the parts in the order of highest expected temperature to lowest. It seems backwards, however there is no battery heating loop and the batteries prefer to be between 25-35C. So I imagine that with the correct controls scheme and a radiator with enough overhead you could keep motor inverter cool while keeping the batteries "warm" or in their ideal temperature range. I too have heartburn seeing the batteries in the loop after the motor/inverter. Another thing to consider is that the outhouse has the OBC in it which will probably reject just under 1KW heat during charging. this means that the batteries will see some heating both from the coolant and from the process of charging. this concerns me also.

[@celeron55]

I have a similar-ish DIY EV conversion and I agree the inverter should probably go first. But unless the car is ever DC quick charged, the battery won't get that hot. You could probably get away not even running coolant through it. I have CHAdeMO on mine, and we have -20°C winters so I also have to heat up the battery before charging, in which case running coolant through the battery is obviously necessary.

[@smartazz]

Just flip the direction of the flow if needed :)

[@JohnSmith-yv6eq]

@@brandondelgado4153 Program the pumps and fan run during charging? If in a very hot environment while charging...plumb in the a/c as well?

[@MrWhatsHisFace87]

Just sitting here waiting for your channel to take off. Just patiently waiting. Great video. 👍

[@randycarter2001]

The motor is the hottest part. It should be last in the loop. The motor also can withstand the highest temperatures. You want the coldest coolant on the electronics. A fortunate happenstance is you're either charging or driving so the inverter and charger can be in series since only one will active at a time.

[@clayton8or]

“If the coolant gets hot enough to push the cap open that means the car is on fire.” On lunch and currently dying

[@malakiblunt]

as a british person i can confirm we all ware monical's at all times, unless we need glasses in which we wear one in each eye

[@cccpkingu]

"ware"? Begone with you burger imposter.

[@Dukey_H]

we also all have to own penny farthings, its the law.

[@petem6291]

Matt , I really enjoy your videos , if I could offer a little welding tip before welding your aluminum you can warm the pieces up with a small plumbers torch (not a crack lighter) just enough to drive moisture out, and cutting oil, and The coating that is sprayed on aluminum parts to keep them from oxidizing ... Then weld your parts using a cursive( e )pattern with this method your are overlapping and advancing forward , possible filling a void that would later become a leak . I think you will be happier with the look of the finished piece ... Thank you for taking the time to make this video.. Pete M

[@PheonixRise666]

I've never heard of aluminium getting sprayed with an oxidation barrier. Aluminium is crazy reactive but the oxide layer is super stable.

[@corvus1238]

10 out of 10 for the metric conversion. Now all you have to address is the fact that it is aluminium not aluminum

[@InSaNep4nDa]

The mental image of you driving down the road with no covers on the side of the engine bay is awesome, would make a lot of people look twice like where tf the engine at?

[@stefanzelcevic]

its hilarious that tesla is gna open up supercharging after ur last vid, id say sm1 from there still follows you

[@lost4468yt]

I mean decisions like that take a lot longer than that, they must have been discussing it for a while. E.g. it's already open in some countries

[@csn583]

^That, also plenty of Teslans and co-ex-Teslans follow him of course!

[@cccpkingu]

Open it up does not mean anyone will get a go.

[@josealeixo2854]

Most underrated channel

[@rannyacernese6627]

It would be a great look if you don’t install the hood and drive around without an ‘engine’

[@gsftom]

Haha - good call 😀

[@JohnHughesChampigny]

Put a fish tank in there.

[@JohnHughesChampigny]

Come to think of it didn't Revel make a "visible V8"? You could install that.

[@mccarterjg]

Oh my gosh man, You are very knowledgeable in your path, and you are stepping out of your longest known comfort zone and showing us your learning, and then you have those little funny tidbits like the welder cord going through the windows, a very very great combination for entertainment and learning thank you

[@jamesfleming6773]

Brilliant, you’re mind must be working all the time. A very clever person with a lovely dry sense of humour.👍🇬🇧

[@gannas42]

Always surprising how much woodworking goes into these antique vehicle restorations. 😉

[@falkmihi]

Thank you SuperbritishMatt for your efforts!

[@UmmYeahOk]

What a twist. After all this time, I was a GoPro. Who’d’ve thought?

[@csn583]

This is like that first look in the mirror in Soma...

[@CreeperOnYourHouse]

The point of the AC cooling unit is to keep the battery from overheating with the car off. It's to prevent situations like where the nissan leaf batteries would prematurely die because they'd get hot and wouldn't be cooled while charging or just sitting outside. In California, this would be especially important.

[@brianb-p6586]

A Leaf doesn't cool the battery under any conditions... car running or not.

[@CreeperOnYourHouse]

@@brianb-p6586 That's the point. Without the chiller, the batteries degrade. Nissan 'solved' the issue by changing battery chemistry a bit after the first few years, but the overall issue remains without any kind of cooler.

[@MrAlf24]

“The cooling rectangle” I’m stealing that!

[@ShamWerks]

I thought Apple produced rectangles that made anyone cooler?...

[@incognitotorpedo42]

Tesla is very into rectangles. The new Model S has a Steering Rectangle.

[@bnrynlds]

I'm so British my monocle is British Racing Green!

[@ReemerFeddes]

Super British Matt is a good help. Thanks for this.

[@pokeypaul78]

I find it super cool that you have a real anvil. Also, all British cars need wood parts. Of course a Jag needs hardwood.

[@REDCLAYHOMESTEAD]

Wood is a nice touch, really brings out the luxury and englishness of the Jaggg

[@NoxiousPluK]

My favorite series by far currently; can't wait for the next video! Amazing project.

[@Jackofafewtrades]

1:30. The commonwealth thanks you!

[@HalflingRC]

These videos are more entertaining and interesting than B is for Build's videos! Those are great too, but are starting to repeat themselves a bit too much. I like and watch them too, but this channel is my favourite one now!

[@4literv6]

Checkout salvage to savages channel. They are building a sick one off dual tesla drive unit's awd c10 box pickup. Also checkout electric supercar for a homebuilt wide body tesla powered kit car, and electric Plymouth satellite for a tesla swapped 70s muscle car. 😎

[@tuc-dh4df]

In a place called England, your commentary would be in the smart Alec box. Good vids all the same👍

[@david929190]

I like the jumping around. It's how it usually goes.

[@G.B]

Thank you SuperBritishMatt, keep up the good work.

[@gstorhof1]

Super Fast Matt is cooler than tesla powered jag battery

[@RobM184]

When do the shirts and stickers of super British Matt holding his sign that say "all hail the algorithm" come out?

[@SuperfastMatt]

Soon

[@Mike_Costello]

@@SuperfastMatt American Super Fast Mat - All hail the algorithm British Superfast Mat - God save the algorithm

[@tienenaar2295]

How cool would it be if you could make the charging spot under that hood ornemant. :p

[@bertiehogan7880]

I agree, and it would prevent any sticky fingers from removing that beautiful and irreplaceable pussycat. And whilst I'm here, may I add my congratulations on the quality of your project, and your presentation .

[@crisprapper]

My home town built some very pretty cars back in the day. And this is a cool project, I've been following a while but decided now for some reason to drop a message.

[@TheTaitjackson]

I have been watching all your videos all weekend. Awesome work, awesome projects and I dig the dry humor. Keep up the great work.

[@Shiftheads]

Thanks so much for the videos man. You are the guy the ev conversion community was missing. Going to make my swap so much easier with documenting all this

[@hondaguy9153]

The AC compressor doesn't bring the temperature down, it increases the temperature and compresses gas to high pressure. 😅 You're pumping water through a radiator so that's an active cooling system.

[@LordHolley]

Loving this series! Cannot wait to see this thing move.

[@spazda_mx5]

British person here, I just wanted to confuse things regarding our use of the metric and imperial systems. Milk and beer are in pints, but most every other liquid is in litres, including fuel, however we measure how much fuel a vehicle uses in miles per gallon, but a different gallon to the one you use in the US. Larger distances and speeds are in miles and miles per hour, but smaller distances are generally in millimeters, centimeters and meters. Not many people will have an intuitive feel for kilometers and kilometers per hour. Contrary to what I just said, the height of people is in feet and inches, but their weight will be in Stone (which no one anywhere else uses, as far as I know), but sometimes in pounds, sometimes in kilograms. General weights of objects will however be in grams, kilos and (metric) tonnes - usually written as just 'ton', to confuse things - with occasional exceptions using ounces and pounds. Temperatures are pretty much always in celcius as fahrenheit makes absoulutely no fucking sense, unless we have a heatwave (it happens occasionally) when the metric for a very hot day is 100 deg F. Hope this helps.

[@fredericrike5974]

Indeed! It makes the whole thing abso-freakin'-lutely transparent! That must be the opaque mud underneath it, sure it is! It all makes such crystal clear sense now- how come I never saw it before? BTW, where does some dude named Whitworth come into this? FR

[@JohnSmith-yv6eq]

@@fredericrike5974 For enlightenment read the rules of cricket....

[@fredericrike5974]

@@JohnSmith-yv6eq Was thinking about my collection of Whitworth wrenches and the weird "not metric", "not US" found on many British cars from the pre WW2 and post WW2 eras.It was a poor joke, sorry! FR

[@davidgutting4317]

Your probably right about about the cooling but you should consider putting a little water temp sensor behind each of the three modules to make sure they don’t get too hot. I don’t think you will overheat the motor driving in plad mode but the Jag may put up more resistance and hurt the rotor and electronics. The penthouse likely has capacitors in it and they quickly degrade above 75c. The battery case will get really hot if a cell fails and you might want the advanced warning rather than waiting for the magic smoke to let out too. I’m bringing this up because I thought a passive radiator would cool my laser cutter just fine and it cost me a controller and tube. You likely won’t know your killing the electronics for a while and a water sensor (thermocouple) is like $8 each on Amazon.

[@SuperfastMatt]

The pumps I’m using require PWM control, so I’ll have a temp sensor that increases flow as temp increases. I’ll also have a warning output light that turns on whenever the motor is expecting active cooling so I know to slow down.

[@anidiotinaracingcar4874]

For a good weld, I always plug my welder to a supercharger: it's worth the trip

[@Emanmonster13]

I've been having issues with air in my cooling system, and didn't know about swirl pot technology. I'm stealing that. Neat.

[@whatislove127]

Man I can't stop enjoying your content and then you bring the Brit Matt and it made things even better, thank you

[@anidiotinaracingcar4874]

Hello SuperBritishMatt, nice to meet you!

[@jackharper6746]

love your tone of self-ridiculing sarcasm

[@paweszczepanski6738]

ALL HAIL THE ALGORITHM

[@bobpowers9862]

Interesting choice of woods, in the back. I think it's fully in keeping with the patina of an old Jag. Plywood is so.... 'the colonies'. :) So now that the swirl tank is in, you could just leave it as a coolant check, since, you know, you plumbed in that cute little sight tube and all.

[@louwrentius]

I almost missed the hole, maybe add some arrows to the video next time 😡 😆🌷👍

[@JohnSmith-rf1tx]

I bet you do all the cooling work in the body repair episodes.

[@maxxod1]

Regarding the information plate you mentioned. There is a golden opportunity to have a little laugh. You could have one remade and where it has the recommended oil product, you can put something funny, like “nope” or “0.000”. You get the idea.

[@davidepperson2376]

I like watching these with my boy - was very thankful this episode was clean/kid friendly. Thank you. And awesome build man - epic even! The juxtaposition of an old Jag (Lucas electrics lol) and a Tesla drivetrain - mindblowing!

[@mikeybhoutex]

8:12 - THIS is why I watch all these videos. You and the others like SMA, FordTechMakuLoco or even Cleetus. There's something to learn all the time, and this particular time, I learned what I need for a certain project: Beading tool! Thank you so very much! XKCD 10000 moment. Always learnin'! :) I can't wait to see this thing runnin' around, Matt! *thumbsup*

[@mikethompson7046]

Thank you for the conversion. Means a lot

[@rckepka]

I am so glad I found your channel

[@bart9859]

Really cool stuff, every educational. But I have a couple questions: The holes in the firewall, are you going to put patch panels on them too? Second, your radiator, from the camera angle it looks like your bottom outlet is below the steering rack. Shouldn't it be a little above it so that the hose does not rub on it and cause a leak? Really like your videos, and it is making me think about a electric vehicle project or maybe even breaking down and buying a new Ford F-150 Lightning. Thanks for all of the great ideas Bart

[@MoDawdy]

oh, you'll also want the two high spots at both ends of your system, as you have it, for 'burping' after the initial fill. even if the rad had the extended fill neck you could have air pockets at the other end of the car that won't easily purge.

[@erags1092]

This is my new favorite project car on the KZbin's. Keep up the good work.

[@mitchellsnider4198]

How many other engineers, mechanical or otherwise, have an internal monologue that sounds almost EXACTLY like Matt when building things? Thoughts like, "the correct solution to this mess I put myself in lies with the Holy Trinity of Engineering: correctness, cheapness, and laziness" - Thank you Matt, I don't think I'd ever have been able to sum up the technological masochism that is modifying cars to my wife without these videos...

[@DirtSweatGears]

You're in Los Angeles? So am I! I'd love to be able to check out your car some day. I'd like to do an EV conversion to my 53 Studebaker and have been watching your video for ideas and inspiration

[@ashleysmith3106]

Just when I got the hang of internal combustion engines, car propulsion turns into THIS electric nightmare. I don't know what Matt is talking about when he talks electronificationing technology, but he makes it interesting nevertheless, and now I'm hooked on this channel, so I'm ?adding? to the algorithm!

[@davidartina5022]

As a Brit I appreciate your green helmeted friend converting from nonsense to engineering spec units. Have decided to let “ jagwhah” go now but please. It’s al - u - min e um and the correct name for your woodworking tool is a rooter. Thank you and good night. Oh and keep doing this stuff. It’s brilliant. All hail the engineer.

[@scottzekanis]

You've got plenty of room to raise the radiator and get the fill to be the highest point. It would be in your best interest.

[@shannons1886]

This channel needs swag. British Matt shirts ftw!!!

[@NackDSP]

"On the next cooling video" That's how my projects go.

[@EdwardTilley]

Great dialogue and project !

[@yodasbff3395]

Awesome work, you and MacroMachines are my favorite channels. Thanks for the videos 👍.

[@chrisbrookshire861]

Prius technology is legit tho. Toyota engineered the HELL outta that car.

[@RoamingAdhocrat]

Can you change the badge so instead of "3½ Litres" it says "3½ Volts"?

[@hansdietrich83]

Even better 3 1/3 Volts

[@rodasrodas]

Thank you ! If you didn't mention it, nobody would notice the tiny hole.

[@-MacCat-]

All hail the algorithm, and I'm impressed.

[@sinfulf4i]

detailed wooden panels installed before its wired correctly or functional very British.

[@kasuraga]

7:05 Easier method would be to use a bleeder funnel It'll help make the radiator the highest point

[@atan7260]

every episode makes me giggle, this thing will be glorious

[@anthonyhumbert8787]

Ejecting not rejecting. Rejecting would mean it stops the heat from ever forming. Ejecting means to remove heat form the system.

[@patrickrea6574]

Thank you for all the pain you're going through on this build. I'm planning out an ev mod for my 74 Ghia and I'm always looking for hacks to make life easier.

[@marlobreding7402]

I still think that you should have a lighting bolt under your Jaguar hood mascot. A Jaguar riding a lighting bolt.

[@OrdynskyiVladyslav]

Thank you for the metric👍

[@alex4alexn]

Damn you, i just wanted to be kept in the loop

[@TilmanBaumann]

Thanks British Matt. It's much appreciated

[@austindoud273]

The cooling rectangle is now what I will refer to all radiators as

[@BetterCallGatto]

I dont know how impress is the algorythm But i tell u this. Im surprised by tour work and sense of humour Kudos from Argentina Where we have ecto pascales and celsius in here Also kilometers per hour

[@theknivjocke]

Appreciate the metric conversions

[@kwassierufus]

Bloody brilliant post-credit 😁

[@stanleydenning]

SuperfastMat: Where did that picture of the 1929 Model A come from? It looks a lot like the one I used to own. My dad willed it to me. He restored it in the 70s. I was born and raised in southern California just a few miles East of you.

[@jamesmustin7289]

Out house? Your car has every convenience !

[@zuid37]

Swirl pot: "Kind of like a toilet" - You needed Super-not-American-Matt to give an explanation on that one. N-1 continents have never seen water swirling in a toilet.

[@JohnHughesChampigny]

Huh? I've seen swirling water on all 4 continents I've been on. Which ones don't?

[@curvs4me]

Weld a 5/8 bung on the rad and mount a high overflow. Because you won't be able to take off the radiator cap, ever.

[@TheMatBas]

Please keep VIN plate on car when it´s done. It would be cool little touch :)

[@Tugmun11]

keep on keepin on SuperFastMatt, and "All hail the algorithm."

[@alanmony1582]

SFM, You know the radiator doesn't have to sit that low on the frame, right? If you build a riser for it to sit on it might just make it high enough to get the air out.

[@Shady-Shane]

a cunning use of negative 40.

[@shaneblacklord3313]

Just use the swirl pot Matt! Lol! Love your content!

[@gordonaddison435]

Superbly done, cheers.