Making a 60kWh 2011 Leaf

With a tow hitch and three-phase charging and aeromods as well. I hope you're jealous. I'm even jealous, and it's my car!

[@yggdrasil9039]

Wow, a 400km range 1st gen Leaf - great job!

[@singularity70]

Absolutely brilliant work! Many thanks/respect for doing this, and help us all to battle corporate greed.

[@attackroflchopter4403]

You do realize how tight the profit margins are on cars right? Net margins are 1 to 2% Take that crap back to the house....

[@singularity70]

@@attackroflchopter4403 Task achieved. You made me laugh ..

[@taknmyshot]

You are the smartest person I have ever known. So many people have tried to accomplish what you have done. I truly appreciate your diligence. I hope you become wealthy. You deserve it.

[@attackroflchopter4403]

loloolol easy now.

[@musk-eteer9898]

elon as an exception, why most smart people are not rich

[@isharadhanushan2002]

I think the 2021 62kWh battery pack can be installed on the 2011 leaf. They are physically the same size. But it is actually a little bit bigger. I've seen video installing 62kWh battery under the car of 2012,2013,2014 leaf models. If you add extended 18kWh battery on the trunk you will have a total of 80kWh. That means around 550-600km range.

[@tony_25or6to4]

Don't remove connectors, just cover and waterproof them. Please change the cables to orange and put in rubber grommets in the hole into the car.

[@SuperFlons]

You have created one of the best KZbin channels I know! Thank you for that!

[@jeroeneeuwes]

Thanks for the update; I like your magic of 1,5 hours of hard work 🤣 Have fun in Frankfurt!

[@saidbinn9204]

Please share with us more detailed info on how you managed to do this. I got similar car and would love to get similar range. Congrats.

[@t.shonoiki563]

kzbin.info/www/bejne/hXq4m6CfZrR1d7s

[@MrMoises27]

Amazing job you have done Sr. Keep going forward, this will be the future for older leaf models. They really need your help. Congrats.

[@sneakytaniwha1941]

I am a mix of wonder and envy. Well done to you

[@tulkooo]

Imagine replaced 62 kWh + 17 kWh extender, that should reflect into 480 - 560 km in winter

[@ktrontrontron]

Awesome work! Looking forward to more videos

[@micmut8271]

Great job! Fun to se modification done on these vehicles.

[@lolish3k]

So when can i come to you to upgrade my 2012 leaf ;))))) MORE BATTTTTTTTTTTTTTTTTTERYYYYYYYYYY's

[@miaa82]

Yes, me toooo

[@ariesphoenix]

Me also, I wanna upgrade my 2015 leaf

[@MrMoises27]

Maybe you can give a seminar and show how is done and work with other small businesses that are planning to do the same project, together everything is possible. Cheers.

[@mbaxter22]

Fantastic. I love how the Gen 1 Leaf's in Europe are getting a second life with battery upgrades. I'm jealous; my 2013 Leaf SV will probably never get a new battery because I live in the US. One thing I'm curious about: did you have to upgrade the suspension to deal with the increased weight?

[@bossman8303]

Fantastisch werk. Ik hoop dat het allemaal voor mekaar komt.Je engels is ook heel goed maar een brug in het engels is een hoist. Groetjes uit Canada. Ik woonde vroeger in Diemen. Leuk om een Nederlandse video te zien.

[@PeterGroenink]

i axidently stumbled across this channel, yore English is amazing for a dutchman, very small hint of a dutch accent, keep up the doof work, i wil be following the progress from now on. where about are you from in the Netherlands?

[@ezavada]

Will you be documenting the details somewhere for others to work from? I have a 2011 LEAF and would love to do something similar; at very least do the replacement battery pack.

[@PowerElectronicsBlog]

We're planning to sell sort-of-DIY (you still need a hoist and some special tools) conversion kits at some point, but this is still a work in progress.

[@ezavada]

@@PowerElectronicsBlog thanks, that's exactly the sort of thing I'm looking for!

[@gundamzuki]

@@PowerElectronicsBlog This is awesome. I have a 2013 Leaf in need of a new battery. My plan is to replace it with a 40kWh pack from a wrecked 2018-2019 Leaf but will need the CAN bus modification and (semi)proper instructions. Being in the USA, I look forward to these kits eagerly.

[@djchiii]

@@PowerElectronicsBlog That is great news! Definitely keen to know if this kit you produce could be easily adapted to work with a fiat 500e?

[@PowerElectronicsBlog]

@@djchiii We don't think so, there are some peculiarities to that drivetrain that make the use of these modules tricky.

[@dr.projectx5142]

Now this is fun can wait to do it to my 2013 and it has chademo and 6.6kw charger.

[@FlyingFun.]

Fun project and if refined and cheaper options would breath new life into the old leafs, defo needs some rubber grommets around the wiring going through the metal holes in the boot or that could chew through the wire insulation pretty quickly.( I'm sure you did that but just didn't show it right? ) Typical that it is made much more complicated that it needs to be to simply add a battery to extend range , much easier in my RC planes quads trucks etc lol, just parallel extra ones in and I'm done.

[@PowerElectronicsBlog]

Yeah, there are special passthrough boots on the wiring. We do need to figure out how to properly waterproof the unused connectors though.

[@airtime89410]

Well done. Would like to learn more about the 40kw battery underneath.

[@MsMikkiG11]

Let me know when you are coming to the US. I will definitely book you.

[@extremetaz]

oh my GOD you are such a TEASE!!

[@kkaarrsstteennful]

Amazing... I wish I could do this to my leaf.

[@tapaspal2000]

Our Nissan Leaf Gen 1 Battery Modules are perfect for DIY Powerwalls & DIY lead-acid to lithium conversions for your RV, Golf Cart, E-Bike, etc. giving you more power, less weight, longer life and ZERO MAINTENANCE!*If you are building you own pack using these Nissan Leaf Battery Modules please let us know how many of “TYPE A” & “TYPE B” modules you will need. BE SURE TO USE A BMS WITH YOUR PACK!* bigbattery.com/product/nissan-leaf-battery-module-g1/ Use coupon code "Cycle5" at checkout for an extra 5% discount.

[@dr.projectx5142]

Using a crashed bit battery could also extend the range too. Just need temperature reader and monitor it.

[@aufornvic]

Great work, amazing range, I want to be able to do the same. Could you please post details about the type of batteries you have used, or any other suitable types, and also how to trick the can-bus so it accepts the new extender battery. I also have a question, would it perhaps be simpler to keep the two batteries as distinct seperate units, and simply switch over from the car's original battery to the reserve range battery, using a high amperage relay? Or would this still need can-bus modification? And how expensive are these extender batteries? Thankyou for pioneering this project.

[@BaybieK]

We'll all shudder when we find out how much this all cost.

[@alexmac3938]

Thanks for the video! Waiting for continue! :)

[@fpiergentili]

Amazing work! very good video, keep the good job

[@lecramred4453]

Great project! Thanks for sharing. Did you keep the Chademo charging? Do you consider CCS as well?

[@PowerElectronicsBlog]

Yes, chademo is still on the car. We would love to make an adapter to CCS (or replace the charging port entirely), but that is still a ways away. The communication protocols on CDM and CCS are completely different, as is charge sequencing and basically everything except for the two DC pins.

[@dotcustom_ev]

Low range is not a problem Nissan LEAF is your problem. Buy new modules and you will be happy, without any Webasto and twinbats.

[@paulkennett]

That's a lot of range. Impressive.

[@dantyler6907]

A tow hitch? For a Leaf??? Maybe...you could tow a toy.

[@m.necatisepetcioglu4391]

Isn't 2012 Leaf has 8 years warranty ? Why people are lookign for to replace their won battery simply go to nissan for warranty? I am confused.

[@homeowner8117]

How much is the extended range battery pack in the trunk Please?

[@fordwebster8113]

Fascinating! I don't think you mentioned it in the video, but how much space have you lost in the boot? Also, how much did this cost you? Is this actually scalable for the mass market currently, or is this still a proof of concept?

[@PowerElectronicsBlog]

We sell this - the extender battery is actually final, the 40kWh battery not yet. As for scalability... sort of, we're still a small company so we can expect to do no more than 2-3 cars per week. The entire conversion is quite expensive, costs more than the car costs second hand.

[@NazmulIslam-bz7td]

@@PowerElectronicsBlog hi please send me your contact information please

[@ajayrajaa4117]

When are you doing this to the KIA Soul EV. Looking forward to that Video. You are a Genius; MUCH RESPECT !!!

[@susihormon7821]

Heureka....lets go to the IAA Frankfurt and show the world whats possible. Because Nissan in not there...you would represent all the old customers which Nissan wants to get rid off. Forget the other mods...a working car would make more sense.

[@zilfondel]

He says he is going

[@susihormon7821]

I‘m sitting next to him...

[@premmirissage4409]

Great work. Can you tell me where you biy the heavy duty springs to compansate the extra load. Appriciate

[@__-cy9mv]

Do you have a github page detailing some of the software aspects covered in this video?

[@PowerElectronicsBlog]

Not yet, will be setting that up after hardwear.io!

[@notsonominal]

@@PowerElectronicsBlog news on the update?

[@ndiggadee2663]

On electric scooters when they have double battery pack they have 2 chargers for each battery pack.

[@samusaran7317]

Did you add a thermal battery management system?

[@sc7983]

Like the corvette behind 1973???

[@waywardgeologist2520]

Just waited for solid state batteries to come out in order to avoid taking up the trunk space.

[@watahyahknow]

im working on buying a smart fortwo electric , the normal factory range is about 100 km , have you worked on these cars and is it possible to put extra batterycells intoo this car and have it actually work the same as youre nissan leaf

[@Realhedgehog]

I wish you would have showed us how you did this. I want to do it but you provided zero information.

[@marchkang]

It is going to be my next pet project! Thank you.

[@DerBlauzahn]

Great Video!

[@norieltercero9065]

Interested on extending the battery pack of my nissan leaf.

[@Kallenator1988]

You really are a bit of a wizzard when it comes to battery expansions, well done!

[@krishanalexander]

I recently fitted ZE1 modules to my Nissan leaf 2014 car which had range of 60kms. The SOH of the new modules are around 87% and can do 230 kms at a SOC of 90%. However in some instances the turtle sign appears when I go below 330 volts which I monitor using leaf spy , on a continuous stretch exceeding 60kms. What is the solution to this?

[@mariusavram1468]

Hi Alexander, I’m also planning to add extra 50kw on my Leaf, would you be available for chats and experience exchange?

[@cre8hive1]

add an extra battery back in you your trailer, then you don't carry that extra weight when doing short trips, now there's a new project to think about.

[@PowerElectronicsBlog]

Just ran out of projects, thanks! Oh wait...

[@FPVREVIEWS]

Is there a way to jailbreak the controller, and use any type of battery? would be amazing!!

[@PowerElectronicsBlog]

That is essentially what I made here. I can now connect any kind of battery I like. It won't be fully featured immediately, there is some custom work to do on every type of battery, but it will work.

[@truth6565]

I plan to get a 2013 leaf and replace the rear seats and rear foot well space with a battery box Do you think this is possible? What’s the max mileage you could fit kn the rear seat area? What if you also combined it with one in the trunk? Could you get 300+ miles?

[@derekzmoto1604]

Id like to see this done for a fiat 500e also! This is awesome

[@thatisme3thatisme38]

Do you do this for clients? Where are you located?

[@musk-eteer9898]

I wish I can put that extended battery pack in the back of my 2011 leaf

[@Islamisthecultofsin]

Here is a work around for swapping batteries from Dala's EV Repair. Search for "Nissan Leaf - Battery ID Secrets DESTROYED [FINALE]"

[@iansimons7466]

Hi 👋 with the new pack installed when you put the heater on how much range does it take off the car. My 2013 Japanese built model fully charged takes 18 miles of range off the battery. Q2 can you alter electronically how much power is drawn from the heater on the gen one leafs to improve range and efficiency. 🤓

[@PowerElectronicsBlog]

I guess I could, but the range reduction estimate with the heater on is just a guess; the computer doesn't actually know this in advance. If you use the heater sparingly, it can be less. There are already modifications that let you turn off the heater in cold weather but keep the fan working. We also have seat heaters. These two things together mean we basically never need the heater unless it gets super cold.

[@mjk8019]

@@PowerElectronicsBlog My PTC heater broke this summer. Will try to get trough the winter without it (it's gets to -20 here) by only using heat pump. Will let you know how it goes.

[@PowerElectronicsBlog]

@@mjk8019 My condolences...

[@mjk8019]

PowerElectronicsBlog I plan on buting few 200w 12V PTCs and putting somewhere near the air vents if it get’s too cold. Then having separate relay going from OVMS, so I can activate it remotely.

[@tobyholland1961]

@@mjk8019 I built a 1.2kw 12v system into my heater pipes, with multiple safety controls - stopped me from freezing to death in an Hungarian winter !!!

[@BTom16]

Fantastic! Kudos!

[@siraff4461]

Why would this help rapidgate? It will last longer between charges but then it will have to take on more charge and has more thermal mass which is still not actively cooled. You are less likely to need multiple charges but if you do them it will still heat up just the same.

[@Xunxunism]

I think most people don't drive their EVs for a long distance trip that would possibly incur rapidgate problem. I have driven mine for a 600KM round trip without rapidgate problem.

[@gorazdnovsak3705]

How is SOH on extender after 1,5 years? EDIT: OK I did not know you haven't looked at it. I was planing to ask this question at first video and now I see you are looking at exact same thing right now... and did you say 15.000 or 50.000 km?

[@PowerElectronicsBlog]

50.000km - and we did have one module on the capacity tester already, but I made some mistakes that make those results unusable. It seems like there is about 3-4% degradation, but it might be a little bit more because we didn't use the correct voltage cutoff and had a bad contact. So I'm reserving judgement for now.

[@gorazdnovsak3705]

@@PowerElectronicsBlog Well you drive almost as much as I. 40.000 in a year... And degradation sounds grate for ?new? moduls/batteries in a prototype setup with that distance driven...

[@PowerElectronicsBlog]

@@gorazdnovsak3705 It's 'alright'. Not nearly as good as later Tesla batteries (some of which drive 250 000km and still have 88-90% SOH), but much better than Leaf. That being said I did abuse the car a lot, with 200 QC sessions over that period and a lot of charging to full, all of which is quite stressful on the battery.

[@gorazdnovsak3705]

@@PowerElectronicsBlog well tesla hides initial degredation when pack is new... not sure if you see it on a SOH but I know you don't see it on guessometer... that could also be a part of that...

[@PowerElectronicsBlog]

@@gorazdnovsak3705 Just finished re-testing one module correctly (according to manufacturer spec), did two test runs: 25.117 and 25.114Ah (1116Wh). No measurable degradation at all.

[@MrDiligence2-qx4vw]

So you sell these? Where can I get info on that?

[@robertl.fallin7062]

Is there some reasons for the "battry pairimg" other than allowong Nisson complete control of the owners wallet?

[@PowerElectronicsBlog]

Can't think of a particular technical reason. I think it's really just a control thing. I'll ask a Nissan engineer when I speak to one again.

[@ThanosSustainable]

400km on a LEAF? Jeez... That's awesome! I have a question, though... What if you didn't update the firmware to report the correct range estimation, wouldn't the GOM eventually catch up on its own? Just wondering...

[@gorazdnovsak3705]

From what I know he just reports kWh and range is calculated automatically... But there needs to be translation from new battery "language" to a old battery "language" and some addition of kWh left in main battery and extender pack. So there is no firmware to update per se... Without translating it will not work and without adding extender you would see something like this at the end kzbin.info/www/bejne/kITUeHWGd92Zi6c

[@Aliali-ni6nb]

nice job more details as wiring diagrammed

[@RealHIFIHelp]

Is this safe? I have heard stories up people having their Leaf or other cars, overheat and then causing fires. Is this safe to protect against accidents?

[@paulbradford8240]

Hi, nice work in extending the range of the ev's. I am interested in this as am considering buying a used ev. However, I have a concern. The weight of the extender battery would be in the region of 160kgs. (I found those figures from a company that installs them.) That additional weight must reduce the available weight for the payload (passengers and luggage). With that in mind, it is unlikely that you could use the car legally to it's previous maximum capacity. I have not seen anyone that is doing these conversions make any comments regarding this. I'd be interested in your thoughts on the matter.

[@PowerElectronicsBlog]

The added weight is actually just inside the allowable to retain a full 5-person load as well. But only just with this gen. On gen2/3 the lighter car overall makes it a lot easier to fit inside the GVW.

[@paulbradford8240]

@@PowerElectronicsBlog I am really surprised at that. I thought the GVW (from Nissan) and kerb weight left about 384kgs for the payload. Less 160kgs for the battery, surely wouldn't give you an allowance for five adults.

[@PowerElectronicsBlog]

@@paulbradford8240 According to the import docs for the Japanese built Leaf, it has a specified kerb weight INCLUDING driver of 1500kg and a GVW of 1965, for 465kg of total payload. Minus 4x75kg for passengers leaves... 165kg. Note: kerb weight does not include the spare tyre and is based on 16" tyres and the minimum supplied weight. Real weight is about 25-75kg more in our experience, but this is a fudge factor that all car companies seem to use (we're not quite sure how this works ourselves). For instance the RHD AUS and LHD US Leaf include the spare tyre and have kerb weights of anything from 1525-1575kg.

[@paulbradford8240]

@@PowerElectronicsBlog Thanks for your response. It's strange as some sources show kerb weight as being the vehicle empty on the road, except for standard items supplied with it. So, adding some luggage too could potentially make the vehicle overweight. It's just that I have never seen any reference to that potential. Just an observation.

[@PowerElectronicsBlog]

@@paulbradford8240 Welcome to the wonderful world of fudging numbers. We obviously have to submit our own measurements and calculations to the authorities to get this stuff tested and certified, so you can imagine the headache this causes. Weight for license/legal/tax purposes is apparently something that (sometimes) lives in another reality from weight for engineering purposes.

[@fonsbleijendaal]

A proper cliffhanger! 😂

[@stuck_in_seo]

I know the company in Ukraine which updates leafs with additional battery packs did you update software for it?

[@bitsabe]

Leaf; worst ev we ever had & worst ever made. For value? That's a lot of work for the return. There's no way those mixed cells will ever balance. Never mind these cars have no thermal management to speak of. Shove more batteries in? Now there's even less hot air to circulate around. Lipstick on a pig. Next project - start with one of many EV's that have active liquid/thermal management & you will be a superstar. Good luck.

[@bitsabe]

Rickie - yes

[@bitsabe]

Rickie -many of us who bought 2011's had horrible experiences. Advertised as getting 100mile range when new - it was really just getting 76mi epa. capacity loss was typically 50% by the time the odometer read 70K miles in many warm driving areas. Thin paint, cheep upholstery, cheep carpet, the 2G system cost us >$300 to upgrade to 3G. Nissan SAID they'd sell us a better battery for $5,000 but THEN - they jacked the price up to $8,000 - & that wouldn't even include labor! Even $5,000 out the door would only give us a car worth $4,500. Will never get another Nissan. But glad you feel good about your leaf.

[@Noname-ur1vu]

@@bitsabe You're spot on. I got 2011 Leaf in 2015 with 74% SOH. Brand new they got realistically 73miles with moderate driving on mostly flat roads. Fast forward to now, driving in moderate climate of Bay Area CA, I am at 48% and ~79k. I am getting claimed 34mile range fully charged but driving on freeway for a short amount I am closer to 20. My family have had 2 cars including this one and I will never choose a Nissan again. They scammed the public with their garbage battery technology.

[@evrides]

Noname , We recently started offering Nissan Leaf battery upgrade service in the US. EV Rides (Portland, OR)

[@frankli7035]

Any share about the. can message of the battery

[@sdnalyam]

What does the 40Kw battery pack cost. Cost to get a workshop to do it?.

[@DeerKoden]

Some impressive work you're doing right there! What are the temps under load for the new pack?

[@PowerElectronicsBlog]

it seemed to warm up about 3C on a ~100km drive at the maximum allowable speed (which was ~30% 130km/h, mostly 100km/h). Haven't tested fast charging temps yet.

[@pangrac1]

From where came that extender battery modules? Are they from some EV?

[@PowerElectronicsBlog]

From shredded plug-in hybrids.

[@DeerKoden]

@@PowerElectronicsBlog Prius modules...? P.s. nevermind, Prius modules are still probably Ni-Mh

[@pangrac1]

@@PowerElectronicsBlog From what vehicle?

[@aljudy01]

This is great. The SOH indication was still down to around 8 bars. Is this correct, or is it no longer representing the health of the two new battery packs?

[@PowerElectronicsBlog]

That's not correct anymore, the new packs are at 98.07% and 100% respectively (main and extender battery)

[@aliahamd4519]

good job Which kind of battary you used

[@velanapontinha]

Oh shit, now that I've just sold my 2011 Leaf for 5000€, because it had lost 8 bars (yes, I was driving a Leaf with 4 bars!). There's money to be madefrom this kind of work. Do you take orders? Could I have sent you my leaf for a similar work (minus the extra cells in the trunk)?

[@fonsbleijendaal]

He is about to reopen the order book, you'll be behind the current ones visible on his muxsan.com preoders.

[@aljudy01]

Wow driving on 4 bars. How many kms were you getting by then, around 50?

[@houseofancients]

goed bezig ! ( dutch for well done job ! )

[@MCSanych]

What battery was that with 60kWh capacity?

[@buixote]

I asked the guys @ EV West if they knew of anyone doing 3rd Party Leaf Upgrades... no luck. I'm not sure why *they* wouldn't want to, given the # of 24kWh Leafs out there... maybe Leaf Owners are too cheap! ;-)

[@babaade8395]

Do you sell the extender pack

[@tulkooo]

This is the best thing I have ever seen that happened to a Leaf, I would love to pay you to upgrade our Leaf, do you think it would be possible?

[@PowerElectronicsBlog]

Depends on how far away you live! We only do Europe right now.

[@tulkooo]

@@PowerElectronicsBlog Slovakia, I would bring it to you if you would be willing to do the upgrade, however the Leaf is still under warranty, I would deffinitely like to upgrade it once it ends The car is great, the only thing why I would change the car is range, do you think it is possible? Could I contact you via email or something?

[@PowerElectronicsBlog]

@@tulkooo [e-mail]

[@edcochran714]

I would like to know more about the man in the middle attack a to make the battery work

[@fonsbleijendaal]

He has a video on that. kzbin.info/www/bejne/nn2tlpmMg7hrgKM

[@stevejordan7275]

@@fonsbleijendaal Tak!

[@iKaGe01]

Can this be done to a Tekna edition with the Bose sub? Or can that be in some way moved? Looks really good!!!

[@PowerElectronicsBlog]

Yes, the sub will simply sit on top of the battery box. We extend the subwoofer cable and add mount points to the battery box to make that possible. We've done that with a fair amount of Tekna Leafs already.

[@fryncyaryorvjink2140]

I'm getting one of these eventually

[@alvarotomir5858]

Where are your garage? I've to contact you, thanks

[@unapranker]

What are the planned aero mods? I've been thinking of switching to lighter wheels and lowering the suspension. I currently have the factory steel rims. Not sure if it would be that noticeable of a difference. When I switched from the economy tires to normal all seasons I saw no drop in my average miles per kilowatt, but way better traction. I have been getting 3.7 miles per kilowatt according to the display, I can do better but don't try too. 2014 Leaf here with 60k miles and full bars.

[@PowerElectronicsBlog]

We're planning to sell an air dam, rear skirts, removable flat hub caps, antenna delete. I'm personally also going to attempt some more mods like front skirts (!), wheel wings and mirror tails, but those are kind of ridiculous and possibly illegal so unlikely to ever get sold.

[@ThanosSustainable]

What kind of charger will you be using for 3ph charging?

[@ElectricDriveAfrica]

Nice work. At the end there how come it doesnt show the full 12 bars?

[@PowerElectronicsBlog]

I'm replaying the messages that tell the car it's got 9 bars and haven't bothered to fix that yet. The actual pack is at 98% SOH

[@ElectricDriveAfrica]

@@PowerElectronicsBlog thanks this will be a game Changer. Loads of 2011 and 2012 leafs on used market

[@JamieJones1985]

The leaf wasn't type approved to tow. Wouldn't adding a tow hitch be illegal?

[@PowerElectronicsBlog]

Yes

[@fonsbleijendaal]

@@PowerElectronicsBlog adding the tow hitch itself is not illegal

[@pirpy2]

hello What bms are you using for extender battery ?

[@baileystark7629]

Fantastic video my man! Does the car still work to date with the batteries installed?

[@PowerElectronicsBlog]

Absolutely, it's currently on its second day of charging on the slow granny charger after a long trip :P

[@kennyc3670]

How much would this cost?

[@TheAngryScottsmen]

what cells are you using for the extender pack?

[@bitbit9188]

What about insurance? Who will insure it? Thanks

[@skebokvarnsv]

Great job! What happens if you set the 80% charge mode on the original charger? What range do you get?

[@PowerElectronicsBlog]

Doesn't work properly anymore. But I'm working on an even better feature - being able to choose any percentage you like to charge to.

[@skebokvarnsv]

@@PowerElectronicsBlog Thanks for the information. Will definitely consider a 40 kWh upgrade in the future.

[@curtokay8046]

where do you connect it to the front of the car?

[@DanielSeehausen]

I own a Chevrolet Bolt EV. Range isn't really a major concern (60kwh battery inside), but charging rate is. The max DC fast charge rate I've seen in my bolt is 58kw, but that only lasts til like 20% battery. If an extender battery like the ones you've shown were in my Bolt, would it be able to sustain a rate like that for longer? It drops to 50kw, then 40kw, then 34kw, then 24kw pretty quickly. Then, second question. Why is the charging being limited like this? Would it really harm the battery that much to charge to say, 80% at 1c the whole way? Why can't these batteries charge at 2c when the ones in your extenders can? Would it just increase degradation rate?

[@PowerElectronicsBlog]

Man, there's a masterclass in battery management in here somewhere. I can't really properly explain this to you without some painful omissions, but an attempt: The extender battery in the Leaf improves charge rate mainly by being a different chemistry and having much higher design performance (it's rated 5C continuous and 10C peak, both charge and discharge). And it's got a lower nominal voltage, meaning you can 'safely' push a lot of current into the pack without going over ~4.2V/cell, which is roughly where damaging side reactions start happening. Combine that with the fact that you're splitting the charge over the main AND extender battery, and you get higher charge power without increasing the charge rate of the main battery. The Bolt EV actually has a very similar thing going on. They went for maximum capacity without much regard for charging speed or battery performance, so they chose a relatively high nominal voltage cobalt-heavy chemistry. This gives the pack the same characteristics as the original 24kWh leaf pack: charge to 25% at reasonable speed, then it putters to nothing and you're basically slow charging from 60% onwards. Adding an NCA-type chemistry extender battery would significantly increase charge rate for that pack. As for why these extender packs are so awesome: well, they weigh a ton. You can't have it all. Great performance, almost no degradation, but they have very poor energy density. So you can't really use them as the main battery pack.

[@DanielSeehausen]

@@PowerElectronicsBlog How difficult do you think it would be to replicate the work you've done on the Leaf on the Bolt EV? I'm aware that the Ampera-E didn't sell particularly well in Europe so I'm sure you wouldn't consider it worth your while to do it unless you planned to open a branch in the US or something. I imagine the CAN man in the middle attack would still work, but all the messages would be different so all of that would have to be changed.

[@PowerElectronicsBlog]

@@DanielSeehausen Probably pretty hard as there isn't really a good reverse engineering/hacking community around the Bolt (yet). I'd have to do pretty much all of the legwork, that'd take months altogether.