Chevy S10 AWD, Tesla LDU and Model 3 battery

[retrEVnoc]

Finally getting around to making a build thread. I’ve been making slow, steady progress on this build for quite a while now. It continues to be a learning project for me as I didn’t have much automotive mech or any fab or electronics experience before this.

Let me know what questions you all have, other pics you’d like to see, or ideas/ suggestions. There are some design and build elements that I’m not too pleased with, but don’t have a better idea yet.

[retrEVnoc]

For me the biggest challenge by far has been dealing with the Model 3 modules: both BMS control, and packaging them strongly and securely into the vehicle. I lifted the truck in order to make room for the batteries between the body and frame. The long modules will fit like a glove under the bed and about 6" under the cab. The short modules will go below these, and further forward so that they are roughly equally below the bed and the cab. I've mostly finished the boxes for the long modules, haven't done much on the boxes for the short modules, and have partially completed a mounting system for the 4 boxes. I've both modified and fabricated new crossmembers that will support the battery boxes from above using threaded rod and crossbars. I think my current approach could use some improvements, both securing the batteries in their boxes, and securing the boxes within the vehicle. Would love to hear ideas and suggestions from you all!

[retrEVnoc]

As for the remainder of the build, I've Quaifed all over the LDU with new gearing and LSD, plus the trusty openinverter controller. I've got a prius accel pedal installed and prius power steering (not yet installed). I got driveshaft adapters made at the machine shop as you can see in the pics, but haven't had driveshafts made yet.

I've upgraded the rear springs to heavy duty, replaced front and rear diffs with LSDs, replaced the rear end with one with disc brakes (plus a SOA conversion), installed some junkyard electric fans on the stock radiator...

I haven't really taken apart the dash or interior yet; I plan to do that once I've got my batteries mounted.

[Bratitude]

are you going to get a plunging rear drive shaft made with a support bearing?

[retrEVnoc]

are you going to get a plunging rear drive shaft made with a support bearing?

Yes, that’s the idea, a two-piece rear driveshaft with a carrier bearing mounted to the crossmember behind the LDU. The longer, rear section of the driveshaft will need a plunge or telescopic bit due to the solid axle suspension.

I mounted my LDU at an angle relative to the vehicle due to my front diff being off center over to the left. So while the output flanges are pointing in roughly the right directions, the angles aren’t all perfect, as in they don’t all add up to zero like in an ideal driveshaft scenario. Still don’t know if this mounting decision was a mistake or not. I’m hoping that some double cardan joints particularly in the front will do the trick. In my truck, mounting LDU at a slight angle actually allowed me to get it further up in to the transmission tunnel than if I’d mounted it straight.

[retrEVnoc]

Who’s got thoughts on mounting and BMS’ing the Model 3 modules? I really liked what SuperfastMatt did with his swap. My layout of the batteries in the vehicle will be very similar, but my current design has each module individually boxed. One problem I have is I didn’t buy the whole pack, so I dont have the full penthouse nor the structural elements from the pack like he does.

[Romale]

As for the remainder of the build, I've Quaifed all over the LDU with new gearing and LSD

what is the gear ratio in the Tesla gearbox NOW? do you have 4.11:1 in bridges? what is the size of the wheels and what is the maximum speed you expect? I still can't mature enough to convert my hummer into an electric or a serial hybrid.

[retrEVnoc]

The Tesla gearbox is 4.5:1 IIRC

I swapped the diffs to 3.42 lsd and I have 31” tires but will likely end up moving to 3.08s and possibly larger tires to further increase my top speed and ,more importantly, slow down the motor cruising at hwy speeds

[retrEVnoc]

Damien’s ongoing truck build inspired me to get back on the forum and share my similar build! Long overdue update:

Drivetrain complete with modified LDU and custom driveshafts, and hopefully strong enough

All four Model 3 modules individually reboxed and installed

Openinverter model 3 BMS controller connected and showing bugs with the 23s modules. Tom trying to help debug but he needs a spare 23s BMB which I dont have.

6.6kW liquid cooled charger/ DC/DC installed

Vac system for power brakes installed

Reestablished LDU contactor control in the vehicle

Added a 12v fusebox from Nissan Leaf under the hood.

HV junction box mostly complete with ISH shunt, also have spare contactors for eventual Chademo charging.

Still need to finish 12v wiring

Questions for community:
Best guides for CANbus setup and configuring the components? Im clueless on CANbus. Dont know if any of my components have internal terminations. I know my charger does NOT.

ISH shunt wiring and setup? I downloaded the mfr documentation but still not exactly sure of myself

Does level II onboard charger (-) from battery (-) require going through the shunt?

VCU, I have a CANDue from EvTV which i thought i could maybe use as a VCU but not sure. Wasnt successful in loading GEVCU on it.

[Bratitude]

I have a contact on Facebook with bmb boards (you emailed me I’m guessing?) I’ll he’s on the ev conversion group as well. Ill message you with his contact

[retrEVnoc]

I have a contact on Facebook with bmb boards (you emailed me I’m guessing?) I’ll he’s on the ev conversion group as well. Ill message you with his contact

Thanks! Yea please send me his info! Any luck with your BMS controller Brat? I think youre using the shortest Model3 modules, correct?