[WIP] Leaf to VW Type 2 Campervan

[ianlighting]

Howdy. First post, feel free to put me right on anything (but gently would be nice if posss).

This is probably a first pre-project post as an intro and if I get my sh*t together I’ll follow with more info as a proper thread. Probably.

Was going to add a couple of photos for people to laugh at, but I think I need to read the instructions on attaching photos, so will save them for the next post. It’s probably easy when you know how...

Anyway, plan is…

VW Type2 - to be electrified.
Nissan Leaf - donor of motor stack and BMS
Resolve EV - controller
Brat industries - probably adaptor stuff attached to transmission.

As I’m new to this stuff (but feeling optimistic) I am deliberately keeping things achievable. There will be plenty to contend with I’m sure but this approach keeps a win within sight IMO. Who knows where this will all lead once I’ve achieved this build.

I also gain the easy benefit of 50kW charging via Chademo (or ccs via adaptor) instead of only slow charging which I see in a lot of kits.
Oh yes, this is also in the region of £5k build I reckon.

EDIT from the future - adjusted up to £10k to include a 62kWh battery.

I’ve read about ‘proper’ CCS via other controllers, but to be honest it feels outside my comfort zone at this stage. I’m in learning by doing mode here.


So far…
I have a medium nice VW T2. Eventually will be electrified. But I don’t want to practice on that. So have bought a complete failure of a VW T2, lots of v bad rust and daylight everywhere. I will practice on this.

I have bought a smashed up Leaf (2015), 24kWh batt. It arrives tomorrow.

I’ve agreed to do a course on high voltage EV maintenance and fixing. Keeps the wife happy to know I’ve reduced risk of death a little.

And that’s it, but I think I’m clear on my next steps.

Thanks!
Ian

[ianlighting]

Is it out of order to be talk8ng about a build on this site that is not actually using the Open Inverter board?

What’s the protocol here? Is it bad form?

[Jacobsmess]

No you're fine.

[johu]

As long as it's EV you're fine
In the "full editor" when replying there is an attachment tab below now that your first post was approved

[ianlighting]

Here’s the cheap vw made of burnt flaky crossiants (that’s what it looks like underneath anyway).


And also the broken Leaf that will give it new life!

Once I’ve learnt what I’m doing, the new beating heart will get transferred over to my running VW bus which is better condition and actually legal on the roads. It will then inspire me to do more restoration on my running Vw. At least that’s the plan…

[ianlighting]

I’m editing this post (Dec 2024). Originally (April 2024), it started with the bold heading and what is found below there (and with dozens of other links I saved offline) led me to this site and to starting my own EV conversion.

Since that point I have found some of the earlier trailblazers that enabled everything else, although I wasn’t around, so the exact order of events when the universe popped into existence is hard to determine from where I am.

Anyway, I wanted to add, and doff my cap to
Johannes Hubner - https://youtube.com/@engineersfear?si=UdAoMpsFWHeotj7d
Damian Maguire - https://youtube.com/@evbmw?si=yOp_-L8iDgOHoTrP

Thanks chaps!

Now back to your usual programme…

Standing on the Shoulders of Giants.

The path that got me ready to try my first conversion is a meandering one, as it should be. I'm going to list a bunch of the links, posts, etc that led me here. The actual list is much longer, but if my build turns out to be successful, and you have a question on how i got wherever i got to, this page might be useful. As described in my intro post, I class myself as a beginner, not a hacker or code monkey. So some of the feats of wonder from Damian etc are not in my list as its outside my abilities currently.

Parts I'll use
Resolve EV controller - https://www.resolve-ev.com/
Brat Industries coupler - https://bratindustries.net/product/niss ... coupler-2/


Builds that Inspired
Dala the Great
This is what showed me the possibilities -
https://www.youtube.com/@DalasEVRepair

Dave, South West EV UK
He wrote his own VCU (i know enought to know thats very impressive!) -

Jimmy, EV Swap
Using the same approach i realised i could duplicate. I know he's present on this site too, and has been helpful in responding to comments on YT to me -


Cera from Finland.
Apparently with no experience is doing a superb strip down and EVing of a VW T2 -
https://www.diyelectriccar.com/threads/vw-t2-76.206309/

French guy
VW T25 EV conversion -


German guy - EDIT, sorry, Flying Tools man is Swedish. My apologies.
VW Golf - Leaf conversion -



Other Bits

Ben, Leaf Motor teardown - invaluable


OpenSource EV
Regular updates on FB too
https://www.ossev.info/design/battery/index.php

EV4U
https://www.youtube.com/@ev4u

Dont do this



You now know as much as me.
Since I dont know very much I'll reserve my advice to anyone at the same stage as me to watching almost all the episodes of the series above. Keep a log of things that you think are important and dont be in a hurry to jump into something. Its complicated and you probably want to know you can achieve all the different aspects before spending money.

[johu]

Small correction the german guy is a Swedish guy (flying tools)

[ianlighting]

Small correction the german guy is a Swedish guy (flying tools)

Ah, yes, you are correct. My apologies to all German and Swedish people, and Mr Flying Tools in particular.

[ianlighting]

Take object A and insert into position B. Simple.

Actually, slightly stuck on the aircon currently. Still pressurised on the Leaf and have not found anyone interested to come out and suck it out professionally. Need to sort that before I can get the engine out from what I can tell.

Object A (shown upside down, not my fault)

Position B

[ianlighting]

It’s free… (meaning released from captivity, not zero cost!)

Sorry about photo orientation. Second time it’s done that. Probably a setting I need to work out.

[andybpowell]

It’s free… (meaning released from captivity, not zero cost!)

Sorry about photo orientation. Second time it’s done that. Probably a setting I need to work out.

not sure what you planned to do as far as an adapter goes but I split the leaf gearbox casing and then left the half attached to the leaf motor as a spacer and made an adapter to go from that to the gearbox, here's a link to my post if you want to take a look it's right near the start

viewtopic.php?t=4064

[ianlighting]

not sure what you planned to do as far as an adapter goes but I split the leaf gearbox casing and then left the half attached to the leaf motor as a spacer and made an adapter to go from that to the gearbox, here's a link to my post if you want to take a look it's right near the start

viewtopic.php?t=4064

Nice idea. I’ll have a look at what you did when I have a bit more time. Current plan is to get adaptor plates and coupler from BratIndustries, but nothing is finalised yet, but I have sent Angus an email yesterday I think to move it forward a bit.

Now the beast is free from the old Leaf, I am ready to firm up ideas of measurements.

[andybpowell]

Nice idea. I’ll have a look at what you did when I have a bit more time. Current plan is to get adaptor plates and coupler from BratIndustries, but nothing is finalised yet, but I have sent Angus an email yesterday I think to move it forward a bit.

Now the beast is free from the old Leaf, I am ready to firm up ideas of measurements.

yes there's lots to consider in the whole process budget, timescale, what you want to do yourself and what you can do yourself so many things to consider

[ianlighting]

yes there's lots to consider in the whole process budget, timescale, what you want to do yourself and what you can do yourself so many things to consider

Had a peak at your page that you linked. I havent read all 14 pages though!

I see what you did I think. I will go and consider your approach, although I see you have both equipment and skills that I don't - welding etc. Although I'm up for a challenge, I also want this project to be successful and not end up with a metal scrap yard on my drive due to multiple dead end attempts to do this. So I'm likely gong to continue with a set of purchased parts and follow the road that others have made so there are directions I can follow. I'm pretty confident I can do what my rough plan in my head sets out. Once I've done that, I can imagine there may be other things I could do with different approaches, but that's quite some way off

[ianlighting]

Next stage - received Resolve EV controller, plus I went for supplied wiring looms. Nicely packaged and went together well.

It’s been so long since I pulled the main battery disconnect out that I completely forgot to return when I was ready to test. That took a while to sort out. Idiot!

Anyway, it seems to be alive, but frustratingly I can’t get it to switch from neutral to drive or reverse.

I have tested 350v is getting into the PDM and down into the inverter. My 12v is good and Resolve display starts up after ‘ignition’. But nothing from my D or R buttons (switches and 12v is good there).

More tea may fix it.

EDIT: actually, a gentle nudge in the right direction from Isak at Resolve-EV, all working now.

Just need to deal with an odd accelerator behaviour now. I could not find the recommended pedal, so this may be the cause.

Picture of the place we used to put cars in before this craziness started.

[ianlighting]

And maybe it’s worth a photo of the final VW I hope to convert once all the stars have aligned and I’m fully tested on my initial disaster-bus.

Doesn’t look too bad, but it’s got some rust that needs sorting now before it gets too far, so this EV-ing will also trigger some restoration work.

[ianlighting]

Things have been quiet on my build. I’ve been waiting for my Brat Industries coupler and spacers. They are now in the post! So hopefully I will be able to start making some substantial progress soon.

I was having a panic yesterday on my bench setup. I could switch D, N, R on the buttons and this was tallied on the small OLED, but the motor only reacted in reverse. drive did not move. Had I blown something up? Nope, a stray copper thread on the back of my brake button was shorting. So the brake was ‘on’, preventing driving forward. Panic over.

Sounds like there’s some interesting developments coming down the line with Resolve-EV aswell. Given my slow speed so far, this could work to my advantage.

If anyone reading has gone down the Leaf - Resolve-EV - new CATL modules route, let me know. I’m toying with it. Or you’ve used this setup with another modules type let me know. My plan is to put the modules under the bench seat, so squareish shoebox shapes would work better than long think ones that may waste available space.

[PaulHeystee]

Hi, Nice project. Yes, you need either the VW or Leaf accelerator pedal. I had some small issues with the Resolve setup but mainly stupid stuff (not connected properly etc) Also the type 1 AC charge port needs to be connected, otherwise nothing happens (also)

I am now working to get the Peugeot e-208 (Stelantis) modules, total 50 kWh, to work with the Resolve by pretending it to be a Nissan Leaf/NV200 battery so the Resolve controller will not see the difference. I have a special BMS/controller which can spit out Leaf BMS messages.
The contactors will be opened and closed by the Resole controller, so that is not an issue. It only needs to check the Peugeot modules and send Leaf messages over the CAN bus.

[ianlighting]

Hi, Nice project. Yes, you need either the VW or Leaf accelerator pedal. I had some small issues with the Resolve setup but mainly stupid stuff (not connected properly etc) Also the type 1 AC charge port needs to be connected, otherwise nothing happens (also)

I am now working to get the Peugeot e-208 (Stelantis) modules, total 50 kWh, to work with the Resolve by pretending it to be a Nissan Leaf/NV200 battery so the Resolve controller will not see the difference. I have a special BMS/controller which can spit out Leaf BMS messages.
The contactors will be opened and closed by the Resole controller, so that is not an issue. It only needs to check the Peugeot modules and send Leaf messages over the CAN bus.

That’s very interesting. When you say you have a ‘special’ BMS, can you tell me more? Is this something you have created or from somewhere else?

Although I am very frustrated by the delays (I will update with a new post explaining soon hopefully), it does mean that I have not been forced into a battery decision yet. So I am still interested in options. Would be great to know if your approach is an option I should consider.

[PaulHeystee]

I am still working on the 50 kWh battery. The 'new' BMS will read all moldules and emulate the Leaf battery. This will be a product I can use and possibly also sell to builders.

[T1Terry]

Have you looked at mounting the Leaf under floor battery under the Kombi body? I plan to do this with my MG4 to '74 Kombi conversion, but replacing the gearbox as well and putting the MG4 motor in its place and adapting the half shafts to suit.
this will get around the weakness in some of the Kombi gearboxes and the need to change diff ratios to get the road speed required when the motor is spinning at it's best performance rpm .... plus, I don't need to sort the gear change issues, forward and reverse are just a twist of the gear control knob. The steering will be the big one, adapting the electric steering rack in the MG4 to the Kombi, how do you plan to upgrade the steering to compensate for the added weight up front?

T1 Terry

[ianlighting]

Have you looked at mounting the Leaf under floor battery under the Kombi body? I plan to do this with my MG4 to '74 Kombi conversion, but replacing the gearbox as well and putting the MG4 motor in its place and adapting the half shafts to suit.
this will get around the weakness in some of the Kombi gearboxes and the need to change diff ratios to get the road speed required when the motor is spinning at it's best performance rpm .... plus, I don't need to sort the gear change issues, forward and reverse are just a twist of the gear control knob. The steering will be the big one, adapting the electric steering rack in the MG4 to the Kombi, how do you plan to upgrade the steering to compensate for the added weight up front?

T1 Terry

I thought of the battery under the chassis. Reasons not to for me -
1 - I don’t have a decent workshop, so I can’t put the VW up high to work underneath for long periods. Just axel stands and jacks.
2- I know a lot of people do it, but there’s something fundamental worrying to me about daring gravity not to do it’s thing and pull the battery out from under the vehicle. This is a first build in many ways for me, so I am taking low risk approaches when I come to choices. Putting it inside means it can’t go anywhere.

Although I am keeping the normal gearbox, I expect it will be left in 3rd most of the time. Just like you, I will change direction on the motor using DNR buttons, not using the mechanical gears.

Steering / weight - partially unanswered. But I currently expect to be about 200kg heavier. But it’s built for a 800kg payload, so in theory I’ll be well within spec. They were built for hard work originally. Having said that, I may go for a power steering upgrade. I know a good VW mechanic who has done this successfully on other T2s. But I haven’t gone into detail on it yet.

[ianlighting]

I am still working on the 50 kWh battery. The 'new' BMS will read all moldules and emulate the Leaf battery. This will be a product I can use and possibly also sell to builders.

Well if this BMS of yours comes to life let me know more. Where abouts are you based?

[T1Terry]

I thought if the battery under the chassis. Reasons not to for me -
1 - I don’t have a decent workshop, so I can’t put the VW up high to work underneath for long periods. Just axel stands and jacks.
2- I know a lot of people do it, but there’s something fundamental worrying to me about daring gravity not to do it’s thing and pull the battery out from under the vehicle. This is a first build in many ways for me, so I am taking low risk approaches when I come to choices. Putting it inside means it can’t go anywhere.

Although I am keeping the normal gearbox, I expect it will be left in 3rd most of the time. Just like you, I will change direction on the motor using DNR buttons, not using the mechanical gears.

Steering / weight - partially unanswered. But I currently expect to be about 200kg heavier. But it’s built for a 800kg payload, so in theory I’ll be well within spec. They were built for hard work originally. Having said that, I may go for a power steering upgrade. I know a good VW mechanic who has done this successfully on other T2s. But I haven’t gone into detail on it yet.

If the weight of the Leaf motor is similar to the weight of the VW engine, that will lever enough weight off the steering to balance it out reasonably well, it just depends how far forward you plan to mount the battery pack.
If you are keeping the gearbox, you won't have that area or the engine compartment to use, but you will still have where the fuel tank was and under the back seat area ....... under the floor does keep the weight down low to help with the handling .... the Kombi at it's best has the reputation of handling like a dog on a polished floor

T1 Terry

[ianlighting]

If the weight of the Leaf motor is similar to the weight of the VW engine, that will lever enough weight off the steering to balance it out reasonably well, it just depends how far forward you plan to mount the battery pack.
If you are keeping the gearbox, you won't have that area or the engine compartment to use, but you will still have where the fuel tank was and under the back seat area ....... under the floor does keep the weight down low to help with the handling .... the Kombi at it's best has the reputation of handling like a dog on a polished floor

T1 Terry

By my calcs, Leaf motor stack is 100kg (not incl battery) vs 160kg for VW incl 50% full fuel tank, plus all the other gubbins I don’t need.

Then battery on top which is still to be defined but you can see roughly where I’m at if battery is say 300kg -TBC

If I could wave my arms and it just happened, yes underfloor would be great. But in my real world I’m happy with placing under bench seat and behind front seat bulkheads. Should be good horizontal position if a little higher than ideal.

This is a T2, so handling and performance are not the goal here!