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Scary indeed having that many small wires. Would be easy to fuse the main connection at the original cells, but that design is just bad news all around. My plan would be to interface my extender pack with a "real" Leaf BMS, just a second model which you can pick up surplus for around $100. Where...

My battery now is a 2013 87% SOH battery. The cells were swapped from a salvage Leaf. Range now is 50-60 miles depending on outside temp, my commute is mostly freeway 60MPH. The car behaves like it should with a battery of this health, the only difference is the display still shows 5 bars...

All 3 values vary over time and can go up and down, especially weather related. It's pretty obvious here which you can correlate with the average temperature during the time when I recorded the values :) From the start until 1/3/18 or so the BMS was learning the capacity of the new pack...

They're custom and probably impossible to buy other than from an actual Leaf. You can try 3d printing one: https://www.diyelectriccar.com/forums/showthread.php/showthread.php?t=175674&page=4&amp=1&utm_source=amp

N-MOSFET or NPN relay circuit from here (non-inverting logic) will work: https://www.electronics-tutorials.ws/blog/relay-switch-circuit.html

The contactor drivers in the BCM are only expecting to power one relay, not 2, plus the wiring is going to be fairly far to your extender pack, so you'll want another relay driver to not overload the ones in the BCM.

So 2 major issues: Rated Current: 50A-250A Rated Voltage :42VDC maximum Obviously, 42V isn't nearly 400V. 400V will arc through without blinking that and probably turn it into a smoldering heap. 250A is also a bit below the max current the Leaf can operate at, which I've observed to be about...

If you're getting a full Leaf battery, you can skip the extra contactors, and just use the ones that are contained in the pack. All you need to do is buffer the contactor control signals and figure out how to read from the 2nd Leaf LBC/BMS for errors that would require you to disconnect the...

@map40home, I thought it was better to just share the information here in case anyone else wants it (it's all publicly available knowledge anyways, but I put it together for my own reference): You want to use 3 contactors with your extender pack; 2 need to be full current capable, I recommend...

I mentioned previously, but batteries from a plug-in hybrid make a good candidate for the high drain/high rate charging that the Leaf experiences. Examples are Hyundai Sonata PHEV (what I am using), Chevy Volt, Ford Energi PHEV, etc.

I really don't advise using LiFePO4 with an extender unless you expect your extender battery to be able to handle the full charging and discharging current (120A charging, 280A discharging). LiFePO4 is such a vastly different chemistry than LMO that I foresee a lot of problems trying to parallel...

Seconded, been waiting eagerly for the electronics. I'm sure Mux will finish it just as quick without us pestering him though ;) I'd be happy to help with battery selection/testing for the community, I've already had some experience with this (see my testing several pages back, probably easier...

That's why I'm most excited about Mux's system. Theoretically his method can scale to any future battery tech, if there's a new cheaper source of batteries for example. Personally, I'm still hanging on to my 9.8kWH of PHEV batteries. They'll need to be supplemented with another high drain pack...

Do you have any detail about your extender build?

Is that sarcasm? Hard to believe they would design a car with one component limiting the vehicle's life by a factor of 2 or more. I'm on my second battery at 112k miles and no drivetrain or other issues yet, will be interested to see how far this Leaf will survive, I'm taking good care of my 2nd...

I've got a 2011 Leaf SL which recently got a damaged screen in an accident, so now I need a replacement; where is a good place to search other than salvage part sites (going rate is about $350 for the larger tilt-screen unit in the SL)? I did see one thread on an aftermarket option but it didn't...

I would steer clear of Hybrid Industries; heard some negative reports of scams or sloppy workmanship from them. From this article it sounds like Nissan have begun rolling out their new pricing ($2850) for a refurbushed pack (as opposed to new replacement at $6500), I would contact your dealer...

Very exciting. Still settling in after my move, but I'll be happy to be one of your first US beta customers for the electronics package (I'll be supplying my own battery and a few other components that I've already bought).

Nice work, I'd still be concerned about running your leaf below VLBW, if you take the 82% current sharing that I found empirically, you could be doing up to 10.8A/cell discharge in full throttle or 4.7A/cell charge in quick charge at 50kW. Have you been able to get any current measurements...

I finally got time to process the parallel cell data for LG HE4 in 3p, 4p, and 5p in order to extrapolate how many in parallel I would need to get acceptable charge/discharge rates on not just the LG cells, but also my currently purchased Hyundai PHEV cells, since they're pushing a bit above the...