BMW E "i5" conversion by Matija

General Discussion about electric vehicles.
User avatar
mfox   1 W

1 W
Posts: 63
Joined: Nov 04 2015 3:29am

BMW E "i5" conversion by Matija

Post by mfox » Jul 12 2017 9:51am

Hello,

I'm starting a new project. One month ago I bought this car. I've been wanting to do an BMW series 5 e39 conversion for several years now. I was giving up of this car because they are almost in very bad condition because of rust and they are not good care . I was looking for cupe e46 or e46 sedan , but they are not so good quality and suspension ar also weak. They are also expencive.
Last week I found perfect car for my conversion . It is BMW 520i e39 97 year. It is in very good condition , no rust at all . Inside is almost new. It has some parts to be replaced but nothing serious. He has roof window, wich was priority and collor is also that I like. Two months ago I bought Tesla battery from S 85 , 9 modules . That's 47kwh power.
I have some experience in car conversion. Two years ago I converted an old Opel Kadett.
http://www.diyelectriccar.com/forums...ja-167650.html
And it very good and reliable conversion, Now it has about 19000 km and still going with no problems .

I was looking for powertrain... These days it is working on hacking Tesla drive train, nissan leaf drive train. But they are working on 400 V and I'm scare to play with this high voltage. Don't know if this will working reliable...
For instance if I took Tesladrivetrain , I'll put it on the car gearbox with cluch. There is no room on the car for complete tesla motor+inverter+diferential on the car because of car rear axle carrier...

Image

Image

Image

Image

Image

User avatar
mfox   1 W

1 W
Posts: 63
Joined: Nov 04 2015 3:29am

Re: BMW E "i5" conversion by Matija

Post by mfox » Jul 12 2017 9:58am

Some stuff on car didnt work. Like rear window, front door didnt want to lock it . I replaced both modules on front doors , now is all working . In the meentime , I bought black cotton seats and door panels so the car is going to black. Instead leather in very bad condition. I cleaned the sats and now are like new.

Image

Image

Image

Image

Image

User avatar
mfox   1 W

1 W
Posts: 63
Joined: Nov 04 2015 3:29am

Re: BMW E "i5" conversion by Matija

Post by mfox » Jul 12 2017 10:01am

Today I bought warp 11 electric motor . I wanted some AC from salvaged Leaf or Tesla , but nothing works reliable by now. And it is difficullt to get >400V from 9 tesla modules. So I decided to oldsystem powertrain.

Image

User avatar
jonescg   1.21 GW

1.21 GW
Posts: 3958
Joined: Aug 07 2009 9:22pm
Location: Perth, Western Australia

Re: BMW E "i5" conversion by Matija

Post by jonescg » Jul 13 2017 1:54am

Awesome! Looking forward to how this comes along. The DC motor is a cheap source of power, but not as nice as an AC powertrain.

Also, the Mods may choose to put this in the large EV section. No worries, I'll follow it all the same :)

Any chance you could measure a few things on the tesla Module for me? I'm curious as to what the cooling loop diameter is. It looks to be thin, flat aluminium tube, but I haven't seen any high res images of them up close.

Chris

User avatar
kiwiev   100 kW

100 kW
Posts: 1020
Joined: Mar 22 2015 4:19am
Location: Jindabyne NSW Australia

Re: BMW E "i5" conversion by Matija

Post by kiwiev » Jul 14 2017 7:23am

jonescg wrote:Awesome! Looking forward to how this comes along. The DC motor is a cheap source of power, but not as nice as an AC powertrain.

Also, the Mods may choose to put this in the large EV section. No worries, I'll follow it all the same :)

Any chance you could measure a few things on the tesla Module for me? I'm curious as to what the cooling loop diameter is. It looks to be thin, flat aluminium tube, but I haven't seen any high res images of them up close.

Chris
Dont ask for too many amps from those modules unless you parallel a few mate.
Also what do you want to know is it the cooling you diameter? Have a source for packs in Australia.

We are doing a Tesla hack 420kw hack for a client atm.

Cheers Kiwi

User avatar
mfox   1 W

1 W
Posts: 63
Joined: Nov 04 2015 3:29am

Re: BMW E "i5" conversion by Matija

Post by mfox » Jul 17 2017 4:09pm

jonescg wrote:Awesome! Looking forward to how this comes along. The DC motor is a cheap source of power, but not as nice as an AC powertrain.

Also, the Mods may choose to put this in the large EV section. No worries, I'll follow it all the same :)

Any chance you could measure a few things on the tesla Module for me? I'm curious as to what the cooling loop diameter is. It looks to be thin, flat aluminium tube, but I haven't seen any high res images of them up close.

Chris
Tnx for support :) ,
outer diameter of cooling pipe is 8mm and flat aluminium tube has dimension about 31.8x3.7mm and it goes in 8 rows in module .

User avatar
mfox   1 W

1 W
Posts: 63
Joined: Nov 04 2015 3:29am

Re: BMW E "i5" conversion by Matija

Post by mfox » Jul 17 2017 4:14pm

kiwiev wrote:
Dont ask for too many amps from those modules unless you parallel a few mate.
Also what do you want to know is it the cooling you diameter? Have a source for packs in Australia.

We are doing a Tesla hack 420kw hack for a client atm.

Cheers Kiwi
what is too many ? 700 amp shortly i think it wont be a problem. Those battery are strong , if are they good for Tesla, then are they also good for me :) , Of course I need to put good BMS, cooling and heating .
I wont race this car on the track, I will drive it normaly.

User avatar
jonescg   1.21 GW

1.21 GW
Posts: 3958
Joined: Aug 07 2009 9:22pm
Location: Perth, Western Australia

Re: BMW E "i5" conversion by Matija

Post by jonescg » Jul 20 2017 2:28am

mfox wrote: outer diameter of cooling pipe is 8mm and flat aluminium tube has dimension about 31.8x3.7mm and it goes in 8 rows in module .
Ah, and I believe the P100D models manage to fit more cells in the same space by reducing the thickness of the cooling tube to ~3 mm, and increasing it's height to about ~50 mm for added cooling power.

I am very curious about the material stuffed between the aluminium tube and the cells. It's needed for galvanic isolation, otherwise the cells will be shorting against the loop. It must reduce it's cooling power though.

We have ordered a module from ebay, but won't be here in Oz for a long time. We have to do our research from Google in the meantime ;)

Rube   100 W

100 W
Posts: 255
Joined: Jun 25 2016 10:18pm
Location: Brisbane, Australia

Re: BMW E "i5" conversion by Matija

Post by Rube » Jul 20 2017 4:48am

Great project, I'll be following with interest. The e39 is a nice car to drive and 'll be interested to hear your thoughts on how it drives after the conversion. Good luck :D

User avatar
mfox   1 W

1 W
Posts: 63
Joined: Nov 04 2015 3:29am

Re: BMW E "i5" conversion by Matija

Post by mfox » Jul 30 2017 3:07am

jonescg wrote:
mfox wrote: outer diameter of cooling pipe is 8mm and flat aluminium tube has dimension about 31.8x3.7mm and it goes in 8 rows in module .
Ah, and I believe the P100D models manage to fit more cells in the same space by reducing the thickness of the cooling tube to ~3 mm, and increasing it's height to about ~50 mm for added cooling power.

I am very curious about the material stuffed between the aluminium tube and the cells. It's needed for galvanic isolation, otherwise the cells will be shorting against the loop. It must reduce it's cooling power though.

We have ordered a module from ebay, but won't be here in Oz for a long time. We have to do our research from Google in the meantime ;)
Isolation between cells and tube is with some gume that transfer heat

User avatar
mfox   1 W

1 W
Posts: 63
Joined: Nov 04 2015 3:29am

Re: BMW E "i5" conversion by Matija

Post by mfox » Jul 30 2017 3:09am

Rube wrote:Great project, I'll be following with interest. The e39 is a nice car to drive and 'll be interested to hear your thoughts on how it drives after the conversion. Good luck :D
Yes , Is a nice car and i it seems better quality than e60, and more reliable. I had e60 so I know , I sold him .

User avatar
mfox   1 W

1 W
Posts: 63
Joined: Nov 04 2015 3:29am

Re: BMW E "i5" conversion by Matija

Post by mfox » Aug 02 2017 5:22am

First I wanted to put warp 11 on direct drive. But I change my mine and I will put it on the gearbox. I think motor will last longer and starts won't be with high Amperage. And it is safer with clutch. Car will be about 1.6-1.7 t .
I'm not sure about that , so I want to hear your opinion. I didn't find controller yet.
TNX

User avatar
kiwiev   100 kW

100 kW
Posts: 1020
Joined: Mar 22 2015 4:19am
Location: Jindabyne NSW Australia

Re: BMW E "i5" conversion by Matija

Post by kiwiev » Aug 03 2017 3:38am

mfox wrote:First I wanted to put warp 11 on direct drive. But I change my mine and I will put it on the gearbox. I think motor will last longer and starts won't be with high Amperage. And it is safer with clutch. Car will be about 1.6-1.7 t .
I'm not sure about that , so I want to hear your opinion. I didn't find controller yet.
TNX
Should be OK we did a Hilux with gearbox and Warp 9 thats about 1500 kg it goes OK.

Dont forget DC motors dont like to sit at hills using the throttle to stop them rolling back.

Cheers Kiwi

cheapcookie   100 W

100 W
Posts: 247
Joined: Aug 02 2014 10:34pm

Re: BMW E "i5" conversion by Matija

Post by cheapcookie » Aug 03 2017 3:57pm

good luck with bmw project

Hillhater   100 GW

100 GW
Posts: 11613
Joined: Aug 03 2010 10:33pm
Location: Sydney ..(Hilly part !) .. Australia/ Down under !

Re: BMW E "i5" conversion by Matija

Post by Hillhater » Aug 03 2017 9:49pm

jonescg wrote:
Ah, and I believe the P100D models manage to fit more cells in the same space by reducing the thickness of the cooling tube to ~3 mm, and increasing it's height to about ~50 mm for added cooling power.
.....We have ordered a module from ebay, but won't be here in Oz for a long time. We have to do our research from Google in the meantime ;)
jonescg ....have you seen this...
http://skie.net/skynet/projects/tesla/v ... ttery+Pack
This forum owes its existence to Justin of ebikes.ca

User avatar
jonescg   1.21 GW

1.21 GW
Posts: 3958
Joined: Aug 07 2009 9:22pm
Location: Perth, Western Australia

Re: BMW E "i5" conversion by Matija

Post by jonescg » Aug 03 2017 10:09pm

Yeah, and I eventually found a cooling equipment manufacturer who makes these:
http://www.kaweller.com/battery-cooling ... old-plate/
Scroll down and you will find something which looks very similar... :)

User avatar
mfox   1 W

1 W
Posts: 63
Joined: Nov 04 2015 3:29am

Re: BMW E "i5" conversion by Matija

Post by mfox » Sep 06 2017 4:06pm

I purchase another gearbox from 2.8 engine with only 120 000 km , I bought electrical stering pump and get some visual accessories , M sterring wheel . It wont past on PFL models but with some adaptation will fit :)

Image

Image

Image

User avatar
mfox   1 W

1 W
Posts: 63
Joined: Nov 04 2015 3:29am

Re: BMW E "i5" conversion by Matija

Post by mfox » Sep 24 2017 3:54pm

The wheel is mounted :)

Now is this a different car :)

I was needing to do some adaptation because wheel is from FL and my car is PFL

https://www.youtube.com/watch?v=DP1yynVGRZw&t=3s

Image

New controller has arrive :D

Z1k HV will fit perfectly :)

Image

User avatar
mfox   1 W

1 W
Posts: 63
Joined: Nov 04 2015 3:29am

Re: BMW E "i5" conversion by Matija

Post by mfox » Nov 10 2018 3:31pm

Hello, I wasn't active for some time because of other obligations , and didn't have money to work on the car. Now is in progress.
I Bough M fenders and car is going to paintshop in two months. Is really difficult by us to find some good paintshop to paint whole car.

Image

Image

Image

Image

Image



Image

Image

Image

Image

Image

User avatar
mfox   1 W

1 W
Posts: 63
Joined: Nov 04 2015 3:29am

Re: BMW E "i5" conversion by Matija

Post by mfox » Nov 10 2018 3:31pm

Image

Image

Image

Image

User avatar
izeman   100 GW

100 GW
Posts: 5107
Joined: Jun 21 2011 8:25am
Location: Vienna, Austria

Re: BMW E "i5" conversion by Matija

Post by izeman » Nov 10 2018 5:59pm

Good to see some progress! :thumb:

User avatar
riba2233   1 MW

1 MW
Posts: 1854
Joined: Jun 30 2013 10:23am
Location: Croatia

Re: BMW E "i5" conversion by Matija

Post by riba2233 » Nov 11 2018 11:16am

Following! :bigthumb:
My electric moped: http://www.evalbum.com/4966

My electric car: http://www.evalbum.com/5364

User avatar
mfox   1 W

1 W
Posts: 63
Joined: Nov 04 2015 3:29am

Re: BMW E "i5" conversion by Matija

Post by mfox » Feb 14 2019 7:22am

Car is now at the paintshop.

As you maybe know that I made mennekes type 2 for charging on charging stations
https://www.diyelectriccar.com/forums/s ... p?t=169193

Now I'm making mennekes FEMALE type 2 , by now goes pretty good, and type 2 male that goes on car for charging . OEM type 2 are expencive and those industrial 3 phasis are not so easy to mount. Need to make holder, this one is shorter, so there is not problem with space and it is wery easy to make control for not to ignite the car when is pluged on cabel, wheather has electricity or not .
I brought 3D printing on a new level . With no cracking on layers so easy as before. So Im able to make female this time :D

Image

Image

User avatar
izeman   100 GW

100 GW
Posts: 5107
Joined: Jun 21 2011 8:25am
Location: Vienna, Austria

Re: BMW E "i5" conversion by Matija

Post by izeman » Feb 14 2019 7:32am

As much as i love 3d printing, i would be afraid to see it crack and short out some wires. Did you think about that?

User avatar
eee291   100 kW

100 kW
Posts: 1116
Joined: Nov 05 2015 4:35pm
Location: Austria, Burgenland

Re: BMW E "i5" conversion by Matija

Post by eee291 » Feb 14 2019 7:34am

https://www.aliexpress.com/item/32A-IEC ... a958d13762

https://www.aliexpress.com/item/IEC-621 ... 064ebc28f5

They are not that expensive.
And I certainly wouldn't trust 3D printing over injection moulding.

Post Reply