I did a quick sketch of a diagram of the wiring changes i had to do to finish this update to work with the orion BMS system and the added elcon on board charger and get it to all work together ..... and be happy ......

Fully charged the truck and programmed the new stereo computer system for the wireless torque bluetooth program and as you can see looks great 

here is the connector side will be easy to get to connectors and wire up the orion kit once i have received it llllll

G2 Leaf Modules in a Ranger EV

added contactor box .... BCM.....Orion assy. and started wiring it up ...

first wired in the Orion and amperage counter assy....

updated the contactor box with the bypass and moved the wiring that needed done for the new elcon charger

Put the pack all together installed it and assembled everything ... truck is ready for testing .....

Added a custom bracket and installed the 2500W elcon charger and it gave a place for the avc2 to connect the on board charger with the j1772 connector for charging and added the 2 relays needed to control everything needed .. also added a relay in the dash to control the side of the ignition needed to activate the dc to dc inverter while charging ....

I received my modules so I got some nice aluminum mounting rails tapped them and installed the all thread to mount the modules in place and set them all in ...

bolted the rails down and started mounting them .........

I wired in a j1772 cable and female connector in order to charge the truck ...  I am having a bracket made so I can mount it in the grille behind the door in place of the original old avcon inlet 

here is the front section ... re installed the fan assy and the front section so now it is time to add the original BCM assy. and contactor box and original wiring and then it is a waiting game for the BMS orion kit and continue .....


More to come !!!

Needs a bit of cleaning up but less then 18000 miles and has a title that is always a good start ...........

You can see i bolted the rails down front and back

Now its time to wait ...  I have the first part done so i need the modules to set in and decide how to mount and install them in the empty pack ............ Once i do that then things will move along ...........  I am waiting for the Orion and parts to get going on this project .....

I took the truck for a quick 30 mile run ... for a first run pretty good ... the truck is finished I will do a few more test runs in the future and see how it all works out ... hopefully this adds another choice to upgrading the packs for those that have short runs or live in town or even a vehicle for a teen that is a leash vehicle they have to come home and charge it or at least cant get more then 40 miles away ...


OK so far happy with it i will do some more testing and if there is any changes I will post it ........


keep driving electric vehicles the EV is here to stay .....

added a switch to run the added amp kit i added to adjust the gauges if needed ... also added the db9 to access the orion BMS system and i ran a cable up under the hood for easy access ...

added the DB9 for the orion so a laptop can access the orion programming and set it all up for the leaf modules and cells etc......

added the switch and resistor for my amp increase decrease kit .......

Hooked up the laptop filled in the needed items for the programming and the 100 cells of modules installed ......

everything looks good ....


time to hook up the extension cables .......

There it is all the modules set in place bolted down and ready to wire up ....

Orion wired.... added the wireless HHOBD unit wired it in and tested it .. working good ... 

added the 2 relays needed for orion to control the charger ......

added my amp increase and decrease counter kit to adjust the original gauges ....

I am waiting for the modules to be delivered this week so while i am waiting using one of daves great spoof boards I went ahead and wired it up to make the BCM happy ... it basicallys tells the bcm that all the modules that it thinks is in the pack are perfect .. it splits the 25 sense leads into 25 perfect same reading voltages ...

I use the Orion systems to run the packs and equalize everything so this is just a redundant system at this time ... I really dont want it reading the actual system since this was designed for 25 95ah modules and I am installing 92 cells of 4.1V and only 66AH to start with so I know i am better off just using the total voltage to spoof this system and let my Orion do the actual needed work

I was going to use 100 cells but the voltage curve needs to use more of the top when charging my target is 372V... and these are actually 4.2V cells so for longer life i am picking to charge them to just under 4.1V

this brings me to 92 x 4.1v=377.2V close enough

I will just set the orion to 375V cutoff when charging and i will be at my maximum with a ceiling above the cells so i cant overcharge the cells with the orion watching every cell and stopping the new charger ....

First I found a good shell of a truck ...  it had a pack of NIMH batteries installed in a lead acid truck .... so I removed the batteries and found a owner of a rav4 ev that needed a good set and he now has those .......

I received my orion so I decided to go ahead and get the modules all wired in .... picked up some 14-16 round connectors ... some blue splices some #4 metric screws for the center connector tap on the modules with washers ...  laid out the wiring harness and wired it all up ...  


I have lots of wire tying  and some custom cables and pure copper connectors to build tape and install a couple of more days of the wiring harnesses and i will then take pics and be ready to move on ....

I am starting a new project ....  I am going to update a Ranger EV with under 18000 original miles on it to a small light weight pack of G2 Leaf modules .. I am sure it has already been done but I will try and add some updates to see if it can be a little more viable to be a daily driver with a short commute person ...  i am looking for a approx. 40  mile range for it to be a vehicle that a guy could use to go to work pick up supplies etc. 

things a guy usually needs a small truck for that does not use any gas or at least reduces its carbon footprint a little bit .....


Here we go !!!

First thing is remove everything from the pack to get a good clean start ... i even remove the original fans and have the case down sized since it seems such a waste to have suck a big case on a high speed fan ... the fans on these nimh models has 2 fans one is a circulation fan and the other is to extract air from the case in case of heat .. well built systems .............................

Hooked up my custom made extension cables and inserted the key and started up the truck ...


no errors and everything looks good .....


Next step is to wire tie up the rest of the wiring and test the lid on the pack and seal it up .....


so the next thing is to move forward with that ...


another day or two and i will have the pack back into the truck for testing .....


thats it for today ... will add the finish pictures in a few days ........