So it’s been a while since I posted. Unfortunately not as much done as I’d like but incremental progress.

I’ve swapped the BMS for Orion BMS 2, which supports separate modules for front and rear packs. Front pack has been tested and reports cell state over the CAN bus.

The dash layout has changed with BMS gauge and Curtis gauge visible. Garmin DriveAssist with navigation, backup camera, and assorted alerts such as following distance, lane deviation, etc. Also fitted a Rockford Fosgate marine head unit with Bluetooth.

Minor bits’n’pieces are getting the 12v system back together (with Tefzel wiring because it’s easier to find that an TXL), testing the motor controller and debating throttle options, rebuilding the brake system with EBC rotors and pads, and fitting up the charge port.

BTW, the Orion BMS 72 is available at mate’s rates if anyone wants it.

Replaced the questionable 14″ wheels with correctly sized 13/14 staggered set of RS Watanabe rims with Bridgestone Ecopia NH100C tyres. All ex-Japan.

Fitted up the electronic handbrake this weekend. The silver button is the handbrake switch. Still need some custom cables… Thought I could use the old ones but the actuator needs to sit too far forward and then hangs too low  for this to work. 

Also learned about Rivnuts and PlusNuts – much easier than welding nuts to thin metal in tight places, and lets the mounted part sit closer to the surface. 

First iteration of the lower rear subframe is in place and holding the rear battery boxes.  Heaps of room. 

Fibreglass bonnet looks good and saves 10kg.

We’ve got a lightweight fibreglass bonnet under way now. The main aim being to offset the extra kilos of the front battery pack. It’ll be interesting to see how it turns out, but if nothing else it’ll be significantly lighter than the stock steel one.

Big thanks to Carboglass for this one.

I made up a frame for the motor controller a while back so it sits over the motor. Not much room to play with here! You can also see the rear battery boxes in position but not yet mounted up.

Turns out that this welding caper means brackets and fabrication are fairly easy. Lots to learn though, like don’t use that zinc coated massively overpriced product from Mitre 10. Steel & Tube have the good stuff for a fair price.

First cut at front battery box supports is shown here, reusing existing bolt holes. Might have to do it again to make it pretty, but it’s good enough to move on with and takes my weight without complaint.

There was a small rust hole and a lot of corrosion in the boot so I figured that was a good place to learn to MIG weld. It came up OK in the end after a few coats of paint.

Bluetooth OBD2 interface to broadcast the data on the CAN Bus that links the motor controller, BMS, and Charger. Data will be displayed by Torque App on running on Android. Screen layout TBD but here’s a starting point…