Mazda RX-8 Tesla SDU conversion

[Dylan Witt]

nearly 7 years ago i started a conversion on a Mazda rx8 to electric using a 2015 Toyota Avalon hybrid transaxle and two Prius prime lithium battery's. over the years came a new job which caused less time to work on the project, a LLC I've started for electric car conversions. well update for the past year i had zero testing on the EX-8 and started work on my hybrid diesel system using kia 2015 optima hybrid MSG for use on charging/driving the car using diesel as a limited range extender. this quest involved tons of hours of testing, destroying several prius 3rd gen inverters due to my mis connections of the battery power input. now with proper wiring harnesses for the msg's and prius inverters im planning on using one for the charging of the hybrid battery. full two prius prime hybrid packs at the nominal voltage of 360 and i think the cells tested at or around 25ah from 4.10 down to 3.35. running both pack together will give us roughly 16kwh 360 volts. now to present day work i found a cheap tesla SDU at a local junk yard from a totaled tesla. im posting a update to the current tesla sdu and mazda rear subframe. also would like to note that my old youtube channel wont have as many updates on this project and since the LLC creation im using a new Channel AppalachianEV with the videos of this project car. Big thanks to a few members of the fourm on helping with the control board. Will be posting a video soon.

[Dylan Witt]

link to the test video. glad to see it spin. although the web interface says its in reverse but the rotation is correct for the motor and mazda to be driven forward. unless i missed a picture where the motor is turned the other way.

[Scrappyjoe]

Hi Dylan,

Did I understand correctly that you have gotten an HSG working as a range extender via the Prius inverter? If so, please let me know - I’m looking at doing this as well, so learning the pitfalls from you would be very helpful!

[Dylan Witt]

yes, and no. i was using the HSG to charge batterys using a small engine. but then found a larger yet small three cylinder yanmar 3tnv70 that i mounted the HSG to. i have yet to get the engine mounted in the car in such a way that makes everything fit. i will post an update once i have it running. i am mad at my self due to the fact that these generators only produce about 10-15 amps, its enough to charge the battery and if driving at a constant speed could keep the battery from draining. i have six of these generators four are the kia/Hyundai style, the other two are smaller housings for a kia niro hybrid. i will probably end up using them due to the smaller housing and both instead of the one. i will keep posts updated.

Hi Dylan,

Did I understand correctly that you have gotten an HSG working as a range extender via the Prius inverter? If so, please let me know - I’m looking at doing this as well, so learning the pitfalls from you would be very helpful!

[Dylan Witt]

update for the diesel tesla Mazda rx8. i did just finish the engine install and have fired the engine to see what the voltages are at idle half and full throttle , 3000 engine rpm. idle is 108vdc, half 196 vdc, and full is around 290 volts. the engine is governed at 2800rpm but i have adjusted to get 3000rpm. engine driven pulley is 24inches, the HSG is 6.85 inches. 1-3:43 ratio. good possibility i will be using gen three inverter in charging mode with the diesel engine throttle set for 1800rpm, allowing the governor to adjust the throttle according to load from the inverter as it charges in buck boost mode. i would appreciate some help navigating the software and maybe something custom to use a web app on a tablet to adjust amperage. i only expect 10-15 amps from this HSG, but will be adding a second generator for more amps as this car has now became a test platform and might get replaced with another vehicle soon.