The ExoLeaf

The ExoLeaf Attempting to make an electric Exocet using Nissan Leaf bits. This could be fun, or fail 😬 This could be fun, or fail. The plan seeeeeems simple enough.

1.

Get Exocet.
2. Get EV bits from a crashed Nissan Leaf.
3. Remove all combustion bits from the Exocet.
4. Install EV bits.
5. Drive over Remutaka Hill. But of course there are some details. Boxes to be ticked include...

* Getting certified for legal road use.
* Putting the batteries somewhere safe (and sensible).
* Not exceeding a gross vehicle mass of 1200kg.
* Installing a speedometer that doesn

't use GPS.
* DC fast charging (CHAdeMO, it's a Leaf after all).
* 230V mains socket output.
* Maybe a windscreen? Be nice if it was finished by the end of summer 2021 - so end of Feb 2022 (this is New Zealand).

Gone into winter hibernation. Just the one winter🤞
02/04/2025

Gone into winter hibernation. Just the one winter🤞

31/12/2024

Couldn't let a whole year go past without an update. Sadly work has been stalled for over a year now. Life, jobs, money, time, workshops - it's all been a bit tricky.

Currently have the frame stripped down, prop tunnel removed, some bits of metal to add strength and make a completely flat floorpan. A jig of the rear suspension pickup points so a custom rear subframe can be made to take the entire leaf stack while retaining original suspension. Most of a low voltage wiring loom made up. High voltage side is mostly ready but there's a change of plan for what was the rear battery box (easier setup and better weight distribution).

Am moving to a new workshop in the new year but there are a couple of customer EV conversion projects there that need finishing before work on the Exoleaf can resume. If all goes to plan should be back on it this winter. 🤞

Front and rear battery box voltage tap harnesses complete, and the high voltage connectors to connect the two boxes have...
28/02/2023

Front and rear battery box voltage tap harnesses complete, and the high voltage connectors to connect the two boxes have arrived.

The BMS is going to live in the front box where most of the modules are, and the contactor/precharge assembly will be in the rear box near the inverter. So along with 2 high voltage cables connecting the boxes there are 24 voltage taps and 12 low voltage signal wires that also need connecting. Those connectors have also arrived, along with their ridiculously expensive pin insertion/extraction tools. Those two screwdriver sized bits of accurately cut and shaped metal with blue handles and orange protective surrounds are like $250. Each 🤯 Having the right tool for the job is half the battle, and it's the expensive half. All connector manufacturers make big bank on their specific tooling, Molex, TE, Amphenol, etc.

Working on the front battery box. Prototyping in laser cut wood, forming the tap wires into the new very not OEM module...
13/01/2023

Working on the front battery box. Prototyping in laser cut wood, forming the tap wires into the new very not OEM module layout. Checking it's possible to fit everything together when it's metal and being installed into the box proper, and that it actually fits in the box.

Low voltage wiring loom is coming together. It'll look a lot tidier wrapped up in some Nitto tape.New favourite tool - ...
24/11/2022

Low voltage wiring loom is coming together. It'll look a lot tidier wrapped up in some Nitto tape.

New favourite tool - heat shink labeller!

Disappointed Facebook "feeling" tag doesn't have an option for "feeling wired" 😆

Wow an update is long overdue; six months, sheesh! Time has been spent following design paths that ultimately ended up ...
24/09/2022

Wow an update is long overdue; six months, sheesh!

Time has been spent following design paths that ultimately ended up requiring unacceptable levels of compromise. So a bullet has been bitten and an idea originally put on the "too hard" pile has been resurrected.

New plan - jettison everything! Gearbox, prop, diff, even the transmission tunnel. The entire leaf stack (including reduction diff) will be dropped into a custom rear sub frame where it will drive the rear wheels directly.

The result - ultra minimalism. This thing couldn't be more bare b***d.

Made a jig from the OEM subframe to locate suspension pickup points in space. Will reuse the side members to ensure suspension geometry and chassis mounts are identical to original. Sides will be welded to new metalwork securing the LEAF stack.

Feels good to lose the transmission tunnel. The handbrake lever will move to the right of the driver - so the cabin floor will be completely flat all the way to the bulkheads. There's going to be so much legroom 🤣

This also necessitated adjusting the battery boxes. Front box will grow to take 75% of the modules. Rear box will shrink to take what's left - and be much simpler without a transmission tunnel in the way.

Have been working on CAD skills too. Inside the battery boxes the battery modules will be secured between pieces of laser cut steel plate.

Battery boxes made by Tunley Engineering from my sketchy CAD printouts. Perfect fits!
02/03/2022

Battery boxes made by Tunley Engineering from my sketchy CAD printouts. Perfect fits!

Hope everyone had a nice Christmas and New Year! Apologies for the lack of updates but I did take a little time off. B...
02/02/2022

Hope everyone had a nice Christmas and New Year! Apologies for the lack of updates but I did take a little time off. Back to it now...

Bracketry, assemble! That has been the focus recently. Mostly bits to secure the batteries and their boxes, but also the throttle pedal and a dashboard to fit inside the existing cowling.

Various electrical system bits continue to be ordered and trickle in - big dual pole cut off switches, many meters of hook up wire, battery box fans and temperature sensors/displays, among other things.

Progress, sometimes fast sometimes slow. Took about an hour to map all the ignition barrel, indicator stalk, and light ...
22/12/2021

Progress, sometimes fast sometimes slow. Took about an hour to map all the ignition barrel, indicator stalk, and light switch pinouts. Then another hour and near total disassembly to find out why the dang horn switch wasn't working. Didn't realise there was a slip ring in there with a contact sprung onto it forming part of the circuit - and of course it was a bad connection until the steering wheel was turned a little 🙄

In unexpectedly fast progress news the high voltage fuses turned up. Am amazed considering the delivery estimate was "31 Dec - 18 Feb". 25A blade fuse for scale - and their price scales at a similar ratio 😣

Need to split this busbar and voltage tap assembly in half, includes cutting 12 purple wires and 12 black wires. Better...
21/12/2021

Need to split this busbar and voltage tap assembly in half, includes cutting 12 purple wires and 12 black wires. Better make a note of the pinouts first!

In other news, ordered the battery boxes today. Though with holidays etc. it'll be mid Jan before they're ready.

Began giving serious thought to the motor. How to securely mount it to chassis and torque bar (though the MX5 torque bar is more of a torque girder), how to mate it to a 1.2 meter driveshaft, and how to prevent 10,000 rpm oscillating the rotor to destruction.

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