BMW E60 2007 conversion

[PetersonOctavius]

I'm going to convert my 525i of E60
- GS450h, mechanically locked in high gear, external oil pump disabled
- tesla gen2 charger
- tesla dcdc converter
- tesla pwn ac compressor
- volvo power steering pump ...or the prius electric rack if it fits

i still need to decide on the battery pack

this is going to be my "2nd" conversion. more like a body swap/upgrade.
ive been driving my converted A4 with the GS450h and camry inverter for over 6months... now i ll remove the parts from the A4 and put them in the E60. this time with a lexus 450h inverter. and im looking to upgrade my 24kwh samsung sdi pack to something with more energy. trying to get something in the range of 40kWh.

i will try to document it...video wise on tiktok/youtube and text/picture wise here on the forum

[johu]

Will be interesting to see how much it speeds up conversion when you "just" transfer an already functioning system

[PetersonOctavius]

Ill try to install the GS450h before the end of the year.
i think i can manage most fab-work this year...except for the battery pack
im still trying to add the E60 to zombie, new territory for me

[Bigpie]

Is the e60 different to the e65?

How come you're ditching the Audi?

[PetersonOctavius]

E60 diifers from the E65
different canbus IDs etc.
i got the E60 source file from Karim but i still need to understand how to add it to the zombie original file.

the audi was kind built in a hurry, i usually dont care about looks, functionality over aesthetics.
but now that its driving reliably, i want to make it nice, but the audi is from 2004, the interior is kinda torn apart, headliner droping, cant use the gauges, ac controls unuseable...
also its rhd, here on the island we drive lhd. rhd is allowed, but id prefer to go back to left hand drive.
the E60 i 10times nice inside, and now with the knowledge ive acquired i think i can make a better conversion.

[Bigpie]

Ahh, that makes sense. Now you know you can do it, you're going to do it to a nicer car.

[Gregski]

any chance you can dyno the car as is powered by the Camry inverter so we an compare it to the Lexus inverter later ? and don't mean to make this build / post about me at all but I just launched a new video series where I hope to compare the Lexus, Camry, and Altima Inverters using the Lexus GS450h transmission, and if you have any videos of your Camry build I will add them to the video description, as I am looking for real world examples

[PetersonOctavius]

Hey Greg, i already started taking the audi apart.
from what i recall my setup always peaked at about 130Amp 386V when i floor it with a full battery.
i calculated that to be around the 60hp that the hybrid camry has when its driving on electric power.

[PetersonOctavius]

https://batteryhookup.com/products/used ... 0624915618

i think i like those ones , they appear to be LG chem 6s modules. im getting 17 instead of 16 (the conventional 96s pack on evs) for 102s, theoretically 47.6kWh.

102 x 4.2 = 428.4volts full, but my AC compressor and DCDC can handle up to 420V.
so 420 / 102 = 4.12v , im going to set my max charge voltage to 415volts

according to the measurements found online i can fit at least 15 modules in the trunk...but i ll share them 9-8 or 10-7 between front-back for balance.
tesla slave bmses with simpBms is the plan.

[PetersonOctavius]

Happy new year!!!!

Had to go on small vacation with my family for christmass 24-27dec
couldnt wait to get back.
Got back the 27th around 6pm....by night the GS450h was out of the Audi.
since then ive been working non stop and today jan 1st, inverter and gs450h are installed in the E60.
And of course i forgot to film, so here are some pictures.

later today I am going to start with wiring the VCU to the car.
then install the Gen2 DCDC and charger where the fuel tank was.

[PetersonOctavius]

today Jan 5th i put the car back on its wheel and test drove back and forth. no power steering nor brake boosting yet.
i have on issue:
when Mg2 only is enabled and in drive, the car moves. when in reverse no motion, rather the whining of the inverter becomes louder
when mg1 only is enabled and in reverse, the car moves, when in drive no motion, rather the whining of the inverter becomes louder

anyone knows about this issue? ill be searching on the forum in the mean time

[PetersonOctavius]

the car is almost done, going for inspection in the week of 19 january.

i did install my not so old 24kWh Samsung SDI goodness for the time being while waiting on 16x2.8kwh LG chem modules to arrive.
i m almost do with the HVJB wiring so i can do a proper test driving.
only thing missing is to install the AC compressor and some minor adjusment on the zombie code to fully use the E60 gear shifter.

[PetersonOctavius]

And today, i drove the car from my dad's farm, where i was building it, to my house.
then from the house to a garage close by to check what the heck is that sound.
turn out i installed the GS450h to high, the guibo is slight bent. ill try to drop the rear of the GS lower tomorrow.

[Gregski]

Happy new year!!!!

Had to go on small vacation with my family for christmass 24-27dec
couldnt wait to get back.
Got back the 27th around 6pm....by night the GS450h was out of the Audi.
since then ive been working non stop and today jan 1st, inverter and gs450h are installed in the E60.
And of course i forgot to film, so here are some pictures.
IMG_9657.JPG
IMG_9649.JPG
IMG_9644.JPG
IMG_9643.JPG
IMG_9617.JPG
B08E544E-B368-455F-A2DF-0F878788E790.JPG

later today I am going to start with wiring the VCU to the car.
then install the Gen2 DCDC and charger where the fuel tank was.

I am so not That Guy, I'm not, I'm not, I'm not, but... this man has worked too hard (and FAST) to not have his work presented properly

B08E544E-B368-455F-A2DF-0F878788E790.JPG (27.49 KiB) Viewed 368 times

IMG_9617.JPG (28.9 KiB) Viewed 368 times

IMG_9643.JPG (41.42 KiB) Viewed 368 times

IMG_9644.JPG (30.76 KiB) Viewed 368 times

IMG_9649.JPG (32.48 KiB) Viewed 368 times

IMG_9657.JPG (36.79 KiB) Viewed 368 times

[Gregski]

the car is almost done, going for inspection in the week of 19 january.
394D48C4-19E9-4B74-A722-0A79378605A2.JPG

i did install my not so old 24kWh Samsung SDI goodness for the time being while waiting on 16x2.8kwh LG chem modules to arrive.
i m almost do with the HVJB wiring so i can do a proper test driving.
only thing missing is to install the AC compressor and some minor adjusment on the zombie code to fully use the E60 gear shifter.

394D48C4-19E9-4B74-A722-0A79378605A2.JPG (26.5 KiB) Viewed 366 times

[Gregski]

And today, i drove the car from my dad's farm, where i was building it, to my house.
then from the house to a garage close by to check what the heck is that sound.
turn out i installed the GS450h to high, the guibo is slight bent. ill try to drop the rear of the GS lower tomorrow.

IMG_9833.JPG (27.96 KiB) Viewed 365 times

IMG_9832.JPG (32.71 KiB) Viewed 365 times

[Gregski]

and not having this glamour pic right side up, is grounds for having your EV Conversion Card revoked

IMG_9836.JPG (32.16 KiB) Viewed 364 times

card-revoked-cancelled.gif (814.57 KiB) Viewed 364 times

[PetersonOctavius]

HAHAHAHAHAHAHAHAH Thanks Gregg...
after working hard...i get home and just upload those pics ...as is where is

[PetersonOctavius]

annnddd. today jan 20th, 2026......road legal
still need to install and plumb the AC system...but i can drive it to the shop.
im suprised...did it in less than a month...

idontknow why the pictures are sideways...sorry Gregg

[johu]

Someone had the brilliant idea of putting orientation information into jpg. So now it's no longer just how the picture is "naturally" rotated but also how the producer thinks it is. Once that info is lost (apparently on thumbnail creation) the pic is sideways. You'd have to open and rotate every single picture on your computer to prevent.
Or I find a way to augment thumbnail creation. Observe how it's correctly rotated when clicking it.

That said 1 month is monumental

[Gregski]

Someone had the brilliant idea of putting orientation information into jpg. So now it's no longer just how the picture is "naturally" rotated but also how the producer thinks it is. Once that info is lost (apparently on thumbnail creation) the pic is sideways. You'd have to open and rotate every single picture on your computer to prevent.
Or I find a way to augment thumbnail creation. Observe how it's correctly rotated when clicking it.

That said 1 month is monumental

am I the only one who senses OpenOrientation.org up ahead... lol

[Gregski]

annnddd. today jan 20th, 2026......road legal
still need to install and plumb the AC system...but i can drive it to the shop.
im suprised...did it in less than a month...

idontknow why the pictures are sideways...sorry Gregg

actual photos of Peterson visiting our local Target shopping center in his WHITE car...