Finish it up with j1772 and avc2 inlet and wiring and it is up and charging ... another completed project ...


tested and drove 204 miles on a charge with some charge left ....


​on to some more upgrades and testing .....

Sealed up the pack and that is ready for testing .....

Above cleaned up and got the case ready and the lid cleaned up and ready to go .................

Installing orion kit wiring it up adding the wireless kit and almost done .....

As you can see full voltage is flowing through the case ..... That is just a problem looking for a complete disaster .....


​But as you can see I can get the wrap in a roll to fix the problem ....

This is a upgrade to 230ah Calb cells ... really looking forward to this one!   a 200+ mile per charge vehicle with all the cells fitting inside the original pack enclosure .........  Lets get started.....

Finished contactor box upgrade... orion and wiring etc... new Low voltage cable wired in and almost ready .....


hooking up test cables to test with .....

Dropped pack opened it up and here we are a 100% original lead acid pack ... time to empty it and get these really dead lead acid batteries to the recyclers ......

Mouse proof both the case and the lid ... i have seen many packs damaged by the little critters chewing on wires and causing some major havoc with the rangers .....

Well to my dismay I am somewhat disappointed that the bottoms of the cells are not sealed? my question is why go to all the trouble to wrap the rest of it ... and leave bare metal on the bottom ... 

if you mount these upright on any surface except plastic or rubber there is going to be some massive leakage ...


to prove it i checked between the bottom and the terminals ....!!!

​230AH Calb cells Upgrade

Test fitting the cells in the pack before assembling ...

Removed them all and stacked them up to take in heavy lead acid modules glad to get rid of them ....

Sealed all the bottoms and now they are safe to put the new covers that I 3d print over these it will seperate them to a good safe distance and also get good airflow around them .........

Building the bcm mounting boards and the spoof board and gas gauge kit and adding the amp upgrade kit

Adding the lid riser kit and gluing it in so will have the correct clearance on the cells......

Next remove the original charger and install the new 6.6kw or 3.3kw elcon chargers ....

These are my quick sketches of the layout i am going to use in the packs .....

Not to get off subject but some have asked what actual dimensions available in pack are ....well here is the measurements ....

Lots of wiring and banding and then setting in place and sealing the bottom case to the pack so they dont move ..... lots of assembly and connecting and wiring and strapping to get it put together .....

Time to unpack the new 230ah cells to get ready to assemble