MGA Episode 3 - wiring, wiring, and more wiring

Рет қаралды 19,033

Күн бұрын

Tesla EV charger: www.mustartpower.com/?ref=dgs...
Discount code: ESC10
Hello Everyone! Jeremy from Electric SuperCar here and today I will be doing more wiring than any sane person should.
I upload more videos JUST like this about every week. Be sure to check them out!
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▬ Contents of this video ▬▬▬▬▬▬▬▬▬▬
0:00 - Intro
2:43 - Bus bar designs
3:18 - Battery box fixes
6:51 - Low voltage wiring
9:01 - BMS wiring
10:16 - Motor wiring
12:06 - High voltage cables
14:18 - Mounting the motor controller
15:27 - Running wires
22:56 - Finishing up battery boxes
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Tags: EV build,electric vehicle build,electric car build,electric car project,electric vehicle conversion,ev conversion,electric supercar,electric hypercar,electricsupercar,electric Porsche,Porsche ev,Porsche GTE,How to build an electric car,how to convert an electric car,electric conversion,Electric car conversion,porsche ev,tesla dual motor build, front motor mount, motor mount, tesla motor mount, motor mount, front motor mount, motor mount replacement, car, electric car, electric vehicle, review, diy, car videos, car lover, automotive, lifestyle, Battery box, battery box mounting, battery box DIY,
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Пікірлер: 129

@ElectricSuperCar 3 ай бұрын

Tesla EV charger: www.mustartpower.com/?ref=dgsvhpju Discount code: ESC10

@SeanBZA 3 ай бұрын

Would suggest for those circular military connectors to get the versions with separate pins and sockets, as that allows you to do the connection using either solder or crimp, and put the pins in from the rear, after the shell is in place. They are still waterproof when mated, just you can replace pins and sockets as needed.

@ElectricSuperCar 3 ай бұрын

Yes!! That would be so much better

@michaelcummings7246 3 ай бұрын

From what I remember only the original oem cabling used non-removable pin type connector and all the replacement one we get to replace they had removable pins while I was in the Army. Didn't have to replace them often as those connector can handle a lot of abuse without failing but had a couple that had been poorly placed where they could get hit while replacing other heavy parts and would break them if not careful.

@SeanBZA 3 ай бұрын

@@michaelcummings7246Only rated for 100 insert remove cycles, so I got to be very familiar with pin and socket replacement, as those had often gone with over 10 000 cycles. There were those in high vibration areas, where you replaced the pins and sockets every 200 flight hours, as they were prone to wearing thin from vibration. There you pulled out a pin 0.5mm diameter, where the replacement was 2mm diameter, and the same pin. Yes there were harness sections in stores as well, going from there to a joint further forward, which was not as subject to vibration, and inside the other half you had some slack, before you took out the box and sent it for repair. This was just to solder on long new wires, and replace the chassis mount socket, as it was worn as well. The designers knew this would wear, simply because it sat right above the afterburner heat shields. Box fails no autopilot, as this was the positional feedback for it, and it had to be by the actuators.

@kostyak2008 3 ай бұрын

Prety new here, and definitely enjoying the content. Sorry for the paragraph, but if I may suggest a few observations as someone who works in transportation and wiring, and since you are now building for other people, you don't want warranty work in the future. Absolutely respect the proper crimps and crimpers used. However soldering wires of any kind is not advised, because on a rigid mounted connector, the wire still vibrates and will eventually break right where the solder ends. So, as I've seen someone suggest, use the same MIL type of connector with crimp contacts, that can be adjusted to size of wire, and in your application will be just as waterproof. You can also use a simpler Deutsch DT connector, the surface mount one. Though it is plastic, so depends on application. Regarding high voltage wire and crimped lugs, even with my crazy spec, I can lose up to 2.2% of strands on wire 1/0 or larger and still be ok, so a 300 strand multistrand cable can lose up to 6 of them, and it wont affect anything. And last comment is regarding the screw connectors on the BMS. Common practice is that multistrand wire needs a ferrule crimped on it if it a screw type of termination, as the screw will clamp that down securely. If only strands are clamped, they tend to vibrate from underneath the screw and come out eventually. Could also recommend Phoenix Contacts connector of similar type, but with a spring clamping termination. But as I said, amazing work, very knowledgeable videos, learn something new everytime I watch.

@ElectricSuperCar 3 ай бұрын

Thanks so much for sharing your knowledge

@deanmcmanis9398 3 ай бұрын

Nice attention to detail, and steady progress. It shows that doing work right the first time, precludes doing it over again.

@ElectricSuperCar 3 ай бұрын

Thanks for the comment!

@ianseiuli 3 ай бұрын

I'll tell my kids to watch you for all recreational activities :). This is very educational! Awesome stuff

@ElectricSuperCar 3 ай бұрын

That is amazing!

@John-qc8yy 3 ай бұрын

Worth noting. 40a at 240v is 9.6kw but 15a at 120v is only 1.8kw. BIG difference.

@ElectricSuperCar 3 ай бұрын

What is this reference to?

@John-qc8yy 3 ай бұрын

@@ElectricSuperCar The charger at the beginning of this video. You tested it on 240v and 120v in a Tesla but only referred to the charging amps not watts. 15a at 120v is significantly less than 40a at 240v.

@Draconis8888 3 ай бұрын

I'm still amazed each time at how much detail and effort you put in to these projects. Thanks for showing us your work!

@ElectricSuperCar 3 ай бұрын

Thank you very much!

@lthg18 3 ай бұрын

so well explained, love every video!

@ElectricSuperCar 3 ай бұрын

So glad!

@newscoulomb3705 3 ай бұрын

12:57 "Too many people granny splicing and not double-crimping like you should." - Dom the EV Car Guy

@ElectricSuperCar 3 ай бұрын

LOL!

@SeanBZA 3 ай бұрын

@@ElectricSuperCar Plus you should be using adhesive lined heatshrink, preferably the clear type, so you can inspect to see if the cable ends have started to break with time.

@robotskirts 3 ай бұрын

I wonder if you could get Waytek to sponsor. They’re a great wire and crimp source and even carry txl which is oh so nice.

@karlInSanDiego Ай бұрын

For anyone wondering where you get that high voltage cable stripping/cutting tool, it's a PVC cutting tool found in the irrigation section of any home store. Nice adaptation.

@jeffbaldwin9842 3 ай бұрын

Nice work. Appreciate your attention to detail and use of affordable good tools from you know where. Goes to show that you don't need the "best" of everything to do a good job making it possible for just about anybody willing to make the effort to do just about anything. Keep up the good work!

@ElectricSuperCar 3 ай бұрын

Thanks 👍

@davidgoff5883 3 ай бұрын

Amazing attention to detail Jeremy!

@ElectricSuperCar 3 ай бұрын

Thanks!

@user-aRb00d3r 3 ай бұрын

the man of so many talents! it's always joyful to look at and listen to you.

@ElectricSuperCar 3 ай бұрын

Thanks Friend!

@SwordFighterPKN 3 ай бұрын

Heresy making a MGA reliable!

@jasonharris3873 3 ай бұрын

Very thorough and great finish work.

@ElectricSuperCar 3 ай бұрын

Thank you kindly!

@Nam3Iess 3 ай бұрын

Thanks for the juicy episode and the amount of attention you give to the details is crazy :)

@ElectricSuperCar 3 ай бұрын

Glad you enjoy it!

@floydilian 3 ай бұрын

This is fantastically helpful - thank you!

@ElectricSuperCar 3 ай бұрын

Glad it was helpful!

@EdisonPrime 3 ай бұрын

Awesome episode! exactly the right amoun of nerdy :)

@ElectricSuperCar 3 ай бұрын

🤓

@jimcabezola3051 3 ай бұрын

I'm awed at the care and craftsmanship of your work. May this thing of beauty be a joy forever for its owner. Aloha!

@ElectricSuperCar 3 ай бұрын

Thanks Friend!

@themok3rify 3 ай бұрын

Quality work! Love all your videos.

@ElectricSuperCar 3 ай бұрын

Much appreciated!

@wotterthose4511 3 ай бұрын

If you ever want to change up how you label wires, I use an Epson LW-PX700 label maker for work and you can get cassettes of heat shrink tubing that it will print directly onto the tubing just like on a normal label. I absolutely love that label maker. Super clean job though on the wiring with this thing! I love watching the process

@ElectricSuperCar 3 ай бұрын

Thanks for the tip!

@CoryFleischman 3 ай бұрын

Wow, I love your attention to detail. I like that you really try to do things right. Can't wait to see your next updates! Also... I can only imagine how recording all this and editing it can slow down the actual work. Well done.

@ElectricSuperCar 3 ай бұрын

Thanks! Definitely slows things down

@cinchan04 3 ай бұрын

Another awesome video.. Detailed explanation 👍🇵🇭

@ElectricSuperCar 3 ай бұрын

Thanks friend!

@jeromeandre4915 3 ай бұрын

Another awesome one 👍

@ElectricSuperCar 3 ай бұрын

Thanks for the visit

@lasersterling 3 ай бұрын

Love your attention to detail! Looking really nice!

@ElectricSuperCar 3 ай бұрын

Thank you! Cheers!

@vincentvanhelden6186 3 ай бұрын

Enjoyed watching, very interesting, I have learned some new skills, great work.

@ElectricSuperCar 3 ай бұрын

Glad you enjoyed it

@mikepalmer4763 3 ай бұрын

A few thoughts that occurred while watching your work- water ingress from beneath and through the front grille - how are you protecting the electrical elements? How does water drain away, once in the motor area? What IP rating do these elements have? It’s great to see that you’ve committed yourself to making a business out of a hobby. Make sure quality is maintained, to protect yourself from future issues.

@ElectricSuperCar 3 ай бұрын

Noted

@philipgrice1026 3 ай бұрын

It's an MG. MG's don't leak! 🤣🤣🤣🤣

@cvicracer 3 ай бұрын

Awesome work

@ElectricSuperCar 3 ай бұрын

Thank you! Cheers!

@mattsawesomestuff1559 3 ай бұрын

Jeremy - Took a scan through half the comments and didn't see anyone mention it yet... the SuperSeal seals (yellow ribbed things) are supposed to be crimped onto the back of the pin itself. Fancy superseal crimpers have a stepped die on them to load it all in at once, cheaper ones just have different spots for "pins" and "seals" and you do one then the other, and sometimes require a helping start. You don't want them waggling loose on the wire like that though. Also, you need plugs to fill any empty spots, else the superseals don't seal all that that super, as they'll have open spots for water to ingress, defeating the purpose of every other entrance being sealed. Doing this as a business, your accountability is 1000x what it used to be as a hobby, so, even if it's probably fine, you probably shouldn't be cutting those corners.

@ElectricSuperCar 3 ай бұрын

Thanks for the comment!

@MikeHarris1984 3 ай бұрын

I have that same hydraulic crimper.... for big cables like that, it is a life saver!!! I also like to use coper connectors with nickel coating, and inside the conector, I use a wire brush to get the coating off and down to bare copper. Then I brush a libberal ammount of FLUX inside it covering allt he surfaces. I then stick in the wire, and crimp it solid, and then mount it in a Vice and take a torch to heat up the connector (being carefull not to touch wire insullation, and holding it solid and not letting the wire pull at the connector so everything is held in place. Then you will see the flux boil away and you can take the solder and lightly tap it a few times and when its hot enough, you will see it melt immidiatly and pull itself into the open speces of the connector. I keep doing that for a few seconds until the connector is full of solder and the wires are all sealed in. Then let it all cool down naturally. DO NOT dunk in water/cover with a wet rag, as the sudden temp change does set the solder up, but can cause micro cracks leading to a broken/flakey connection over time. I know its not needed/required with crimp connectors, as they have the solder connectors that are supposed to be done that way (see them on the older OEM cables, or alot of pre-made off the shelf cables at like VautoZone, or Oreally's), but just an extra step I do for piece of mind. So I have perfect crimped cable tight, and soldered connector and flooded the conector pockets with solder so no moisture/condensation/water intrussion can contaminate the wire from the inside out. Then a marine grade heat shrink tubing (the kind with the epoxy glue that melts when you heat it up and then drys SOLID making the connection glued together, and water tight as well.

@ElectricSuperCar 3 ай бұрын

Right on

@Essential_OS 3 ай бұрын

The craftsmanship🤌🤌🤌 chefs' kiss😂

@ElectricSuperCar 3 ай бұрын

Thanks Ian!

@georgec6857 3 ай бұрын

great video

@ElectricSuperCar 3 ай бұрын

Thanks!

@suryavanshib 3 ай бұрын

Awesome ✌🏻✌🏻✌🏻 Keep it up👍🏻👍🏻👍🏻 You remind me my old company where I worked over 9 years🤩🤩🤩 You doing awesome 🥰🥰🥰 Keep it up 💪🏻💪🏻💪🏻

@ElectricSuperCar 3 ай бұрын

That's awesome

@SirJohn2024 3 ай бұрын

Love your mods... 😎

@ElectricSuperCar 3 ай бұрын

Thanks 😁

@rjung_ch 3 ай бұрын

Great episodes, right length with so much in them. Cheers 👍💪✌

@ElectricSuperCar 3 ай бұрын

Thanks!

@Teper303 3 ай бұрын

Nice. Your job looks great. I can't wait for new Videos👍🏽

@ElectricSuperCar 3 ай бұрын

More to come!

@andreyl2705 3 ай бұрын

awesome🔥

@ElectricSuperCar 3 ай бұрын

Thanks 🔥

@mikepalmer4763 3 ай бұрын

Enjoyable watching. I suggest you use a vacuum hose rather than compressed air for cleaning swarf though - it goes everywhere ☹️

@ElectricSuperCar 3 ай бұрын

Great idea!

@corypride5096 3 ай бұрын

Background music is barely audible--which is great!

@ElectricSuperCar 3 ай бұрын

Thanks so much for the support!

@patricke3848 3 ай бұрын

I would highly suggest putting your hyper9 power connectors inside a custom sealed box. This is a major flaw of that motor in my opinion. The motor controller should really go in a sealed box too to protect those connections. Its not a matter of if you get corrosion, you will.

@ElectricSuperCar 3 ай бұрын

Understood

@markedis5902 3 ай бұрын

If you can afford to, go for ptfe insulation on wires. It won’t melt if there’s a fire

@ElectricSuperCar 3 ай бұрын

Nice

@SeanBZA 3 ай бұрын

At least on the safety circuit wiring, and for the CAN bus, where you can get a roll of surplus aircraft grade twisted pair PTFE wire, which not only shields, but is very good at protecting. Just needs 3 pin connectors, and solder sleeves to connect to the braid each end. The sleeve you strip the outer sheath, cut the shield back to 1cm, then fold over the outer, then place a solder shrink over it, slide the PTFE covered shield wire next to the braid, stripped to 8 mm, and shrink the sleeve, so the solder preform melts and joins the 2. That makes it very reliable.

@RealRickCox 3 ай бұрын

I had no idea you could have Send Cut Send do cutting and bending. Too bad we're not all Jeremy level builders. It would be so cool if people could just buy "off the shelf" products like the ones you build to do their own EV conversion.

@RandomMiscShit 3 ай бұрын

You can.. Just Hire Him to convert your car :)

@DD-DD-DD 3 ай бұрын

You can, places like Fellten sell kits and components. Its not cheap and there will always be some level of fab work.

@RealRickCox 3 ай бұрын

@@RandomMiscShit Funny you say that. A couple years ago, I had lunch with Jeremy to talk about maybe partnering on a build... we might have to revisit that conversation!

@ElectricSuperCar 3 ай бұрын

Always looking for the next customer!

@94Discovery 3 ай бұрын

The motor cables need to be crimped on the 2 orange lines , first crimp is the one near the hole .

@tannerbean3801 3 ай бұрын

The silicone wire seals are normally supposed to have that narrow sleeve crimped with the wire insulation...

@ElectricSuperCar 3 ай бұрын

Really? I haven't seen that. Good to know

@tannerbean3801 3 ай бұрын

@ElectricSuperCar your wires will probably seal fine, but it does help to pull the seal into the cavity when pinning the connector

@rickmellor 3 ай бұрын

Another great video. What are your favorite thermal pads for batteries and where do you get them?

@rickmellor 3 ай бұрын

Or… whatever. 🤷‍♂️

@dennisrohm6372 3 ай бұрын

I rewired a 60' 1600 with a Moss factory type loom. It worked fine, except one turn signal. When I called Moss they said the maker had switched a wire so the color didn't match the schematic. It was installed and I wasn't going to remove it to get a correct one. Shame on Moss motors. Abet many years ago.

@RedBatteryHead 3 ай бұрын

Nice build. Perfect car for this. I think you didn't crimp the grommets in that suoer seal connector. They arn't suppose to slide over later on. It needs to go with the pin.

@ElectricSuperCar 3 ай бұрын

Noted!

@Tom-evnut 3 ай бұрын

@@ElectricSuperCar kzfaq.info/get/bejne/l8qDn5pkttDbn58.html

@MrFoxRobert 3 ай бұрын

👋👍

@jamesray9009 3 ай бұрын

are you recording any of the cad stuff ??? for like making the buss bars .. Im curious as to what a good time like should look like I make fairly simple parts and my timeline is SOOOO long I just know there's better ways

@ElectricSuperCar 3 ай бұрын

CAD bus bars are pretty simple.

@keithhagen515 3 ай бұрын

When making 3D printed bus bar prototypes, how do you accommodate for filament shrinkage? Everything I print comes out a few percentage smaller than actual design size. Do you increase the size in your slicing software by a certain percentage?

@ElectricSuperCar 3 ай бұрын

I haven't had that problem, or at least that I have noticed

@CrazySlimMr 3 ай бұрын

Great video! Been watching you for a little bit since Zack showed your work on his channel. How do you like your small business? How does it feel to be self-employed and working on electric cars?

@ElectricSuperCar 3 ай бұрын

It is too early to tell. It doesn't feel like work. It is a little lonely, I miss coworkers. But, hey I have a few thousand friends that I can chat with every video.

@KSA-wo7dh 3 ай бұрын

Looking good! Do you have a supplier for HV connectors like @5:06, and... I tried Deutsch for pin connectors and got no where, at least not with BuyDeutsch. Looking for 44 and 33 pin connectors. Thanks

@ElectricSuperCar 3 ай бұрын

For HV connectors I have used Metabee. For low voltage I have used wirecare.com

@Motoch3 3 ай бұрын

Are you doing any calculations or rules of thumb on the thickness or cross-section of the bus bar to deal with the current? Not to oversize or undersize the copper piece. Thanks

@ElectricSuperCar 3 ай бұрын

Matching cross-section of bus bar that the kit provided. These bus bars can take more amps than the system can provide.

@LaszloBagi 3 ай бұрын

I've got a TR-6 you can do

@ElectricSuperCar 3 ай бұрын

Let's chat. email electricsupercar@gmail.com

@heartofdawn2341 3 ай бұрын

Here's hoping the kit manufacturer is taking notes. It's no wonder the owner couldn't get it to work- and even if they had it could have ended badly.

@omarfermin2283 3 ай бұрын

What kind of battery modules are those?

@ElectricSuperCar 3 ай бұрын

Ox battery modules

@mysterious_czrs 3 ай бұрын

I do not mean to lecture you sinc you probably know more than I do but I think that at 21:30 you are supposed to crimp around the rubber sealing gromet with the part of the pin that normally crimps arround insulation of the wire. But mabe I am mistaken.