Charged up and door closed .... can not even tell we did the changes .....

There we are a finished installation here is the J1772 which is now standard for charging with chargers all over our state now .........

My quick schematic for the relay in dash ......

Next I added a custom J1772 charging port behind the original door and removed the old charging port that is no longer used by any vehicles ....... wired it in to the new charger ....

Here it is all prepared and ready for the new cells

Grind it off and clean it up .....

As of February 2016 this calb 100ah pack is now at almost 41000 miles on this pack ...  the original mileage that I replaced the pack at was 109000 miles

the vehicle as of today has a total of 149800

Close up of the strips I installed ....

There we go some amazing goop and nice cut and fitted plastic strips and its ready for some cells ...

You don't have to jack up the vehicle very far off the ground to get the pack out .. I have a custom made dolly that I use to roll the pack out and back in for installation and removal of the units ...........................

Rav4 EV

Next thing under hood drill a hole install a Anderson connector to charge the vehicle through ...

got the wiring done ... less then 30 minutes of work to install the relay .....

I added a relay in the dash to work with the new charger I am going to add under the hood .....

Add a BMS protection system to digitally protect the cells (LIfepo4) ... it has a wireless system installed that allows the use of a android phone to be able to for free watch and check the cells and it controls the charging of the cells so they are not over charged .......

Emptied all the original NIMH batteries out of the pack and started cleaning up the pack and there is some bumps on the ends and center of pack I am removing to smooth out everything ....

This pack had a crack in it so my brother in law did a bit of fiberglass repairing for me and it turned out great ....

Added the 2.5KW charger and plugged it in ... added some wiring needed to run it all .......................

Next step is to remove the original cover and install a custom built flat aluminum cover to make room for the small 2.5KW ElCon Charger ..........Notice the recycled magnet used from an old television ....

Not to Bore with too many details ... I will take you through the basics I did on this one ....


First off Jack up the vehicle and using very high quality jack stands , a air tool and common sense I removed the pack ... disconnecting the connectors and removing the plastic covers protecting them ....

Here it is all finished up ...  coming up on 28000 miles on this pack and still going ....  great vehicles .....

Added a plastic strip to the sides to hold the cells from sliding around ....

A small 4" inch grinder and removal of any high spots works great to make it so the new Lifepo4 cells can set flat on the bottom ...

at 25000 miles on the pack I exchanged the bms for the new BMS I now use in all the vehicles a Orion ...system

you can check them out at orionbms.com great protection system ........................

My wife now as of this date is the above picture..

February 13th my wifes rav4 ev on the pack I installed

has 69220 miles on the 100ah calb cells still doing well

she is coming up on 70k miles on the pack and over 178000 so far on the vehicle it has so far been a good long life without using fossil fuels ..

I have 2 small solar systems portable at my home producing enough charge to run my shop lights and able to charge one of our vehicles ....

Oh yes, finally install all the cells and wire them in putting the original cables where they belong for the BMS computer system on board to be happy and read the  correct readings needed for the original systems to be happy ....

I then flip it over Clean it all up and I am going to add some sealing strips to where I ground out the high spots since I don't want water going up through the bottom ...

This is my Wifes Rav4 EV ... I am adding some great updates to it..  Replacing the original NIMH batteries to the Newer LifePo4 100ah Calb Cells ...  I will install 96 of them for a 80+ mile range and reliability ............

I purchased this Rav4 EV with 109000 original miles on it with the NIMH batteries and am hoping for another 100000 with the newer batteries ....