all wired up and ready to start charging the vehicle

installed the new android stereo and everything is now in monitoring position

fired it up with no problems time to test drive...

fitting the 6.6kw elcon charger into place and wiring it all up

finished the j1772 custom fit behind the original door assy.

built some custom mounting for j1772 plug and wiring it in ..................

Next step is to remove the original cover and install a custom built flat aluminum cover to install a new fast charging 6.6kw elcon charger  had to add the lid switch to it and then wiring it up

adding the orion bms wiring to the pack and running it up under the hood with custom easy to disconnect connectors

wiring it all up

fitting it all into the case and getting ready to wire it up

fitting cells into the case ....

Finished adding the strips and ready to start installing

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 ...

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 ...

Here it is all prepared and ready for the new cells

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

A small 4" inch grinder and removal of any high spots works great to make it ..this is before changes

New 150ah cells and printed the covers and installed

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 ...........................

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 ....

This is my wifes rav4 EV toyota 2002 ....  I am currently updating the pack and changing the wiring to the latest updates i can do for the vehicle ....................................  2026 updates i am now posting this is a good fit for the pack since it is so small since i am spoiled with all the space i have to work with inside the ford ranger electric trucks .... but here we go ....

Rav4 EV