As you can see above once it is level and ground out to the correct parameters for the new modules I am starting to seal up the holes removed the old center connector which is no longer used in fact can not be used with the new systems if you disconnect the center of the pack without unplugging the main bms systems it will damage them so removing it is a must ................ then seal up the pack with some good quality polyurethane plastic ...............

Sealed up the hole slid the pack back under and bolted it back into the rav4 ev .........

wiring, wiring, wiring

more and more wiring

Lined up the modules and hooked up the powerlab units and did a starting charge on each and every cell ......

NOt to bore anyone there is a relay I add in the dash a few more under the hood as required by the orion bms to control things .... added a hole here and wired in a Anderson connector for any charger wanted to use .....

above is from the original manual for the wiring of the rav4 ev I made the changes in pen for the actual new wiring that is done for the orion in order to read these correctly ....

Using the sealant from the company plastiDip it makes a spray version of totally non conductive sealant I use 3 coats heres coat one

as you can see there is now a hole in the lid that must be sealed so on to doing that ....

assembling the modules hours of taking them apart then putting them back together with custom rods to hold them together

Now its time to add the edge limits to hold the modules in place so more expensive pieces of plastic and sealing it in with amazing goop and just lots of time and patience to place them in and wait for them to dry before moving on ......

Install the orion in the case and now the wiring

Well that's as far as I can take it , now it goes up to Portland to move forward with the rest the owner wants a 5KW charger and I am sure he wants the j1772 mounted externally being  able to access the plug in for easy charging ... since I don't do body work I did not want to cut any holes in the hood etc... and not be able to finish it ... looking forward to see how it ends up and how it works out for the owner .......  until the next project drive ev and enjoy pollution free driving .......

ok gut the entire inside because I have to do some custom grinding and sealing etc to the pack itself 

I like to scrub and clean the pack so I can see any damaged areas the rav4 ev is a very picky leakage pack they built it with it looks like a copper infusion to strengthen the pack it is very conductive  which does not work well with batteries so you need to really isolate the batteries from things like the rivets in the pack as they are very conductive you can do a quick test the same as I do grab a good quality ohm meter and see if there is any ohms leaking through I find massive leakage from the outside ede of the case and all the rivets in the pack I clean everything very well with vinegar and water and then follow that up with a good 3 to 1 mix of simple green and water and thouroughly dry the pack I do this even before I grind out all the bumps and rivets that stick up where the batteries can reach them then I clean the pack again before sealing with a sealer called plasticoat I purchase the same stuff used to dip electric tools in to make them totally non conductive once that is done I have tested and there is no longer any leakage in the pack .........................

This is a Custom 105AH 360V pack I was asked to build for a Friend so I am excited to take on a new installation of high quality cells into a Rav4 EV to see how they work out in a Highly popular fully electric vehicle......

added a connector for the control relays under hood from the orion and put the lid on the pack

Rav4 EV Custom Enerdell Pack

And here we are a 3rd coat set for 24 hours and totally sealed pack checked with ohm meter and absolutely no leakage anywhere in the pack ready to go on to assembling the modules ...................

Heres some more oh yeah wiring

Added a wireless Bluetooth unit so that the pack can be monitored by any android device that can download torque app while driving very nice units I use them in all the ranger ev installs I do and I put in a nice android stereo system in the dash and it can be seen anytime very quickly while driving no question how much you have left in voltage or amperage while driving so you can complain I don't know how much is left so I did not stop and charge !

Flip the pack over and continue with sealing amazing goop and always use a hard plastic to seal up the holes created by grinding and removing the rivets from the top level another time consuming process but a must be done process or it wont work later on ............

and of course more wiring

Plugging and cleaning the pack again with vinegar and water and simple green very time consuming process 

Grinding Grinding... More Grinding then start plugging the holes

Spray coat two

Finally finished wiring and adding the new water seal around the lid area last of the wiring inside the pack is done ......

There you go 1 module assembled and wired ... OK 10 more to go ......................

almost there more wiring

More Wiring

These 3 pics showing once placed where I am happy then amazing goop and seal in the last plastic inserts to limit all movement of the modules finally time to wire in the pack ...  as you can see I was hooking up the high voltage connections with pure copper connectors and then sealing them with high quality electrical sealing tape ..

Fully charged and ready to drive ...

​as you can see from gauges looks really strong a normal rav4 ev charges to approx. 325 to 330V this one is now 360V  a original rav4 ev is 95ah this one is 105ah ....

I added a custom plate to the top of the suitcase wired in the needed avc2 installed a 2.5kw charger and a J1772 unit under the hood ........

​all fits without any other modifications needed .....

OK lets get started I use a great high quality floor jack with a good solid crossbar attachment two pair of really tall high quality 5 ton jack stands a good air compressor and air gun to remove the pack bolts a good Makita battery powered (lithium of course) impact to help in removal of lid bolts etc. a good custom built dolley for rolling it around are all good ideas ...I have a low ceiling so this works best for me ...... less then an hour to have it out and open and working on it ... of course putting it back in is reverse the original manual is a good source for the proper way to remove the pack ... always read the original manuals before doing anything ....... well here we are dropped the pack I will next open it up and remove all the guts ....

Wiring up

Very expensive pure copper connectors custom made for these 48 cell - 105ah -  32.8V modules  need 11 of them for this install ......  hours and hours of work just have to take your time and assemble one at a time ....

and again more wiring

To the left is the original high voltage and sense lead wiring for the rav4 ev

I am setting them in for a good test fit to make sure all my measurements are correct ......