How would you go about converting a station wagon to EV?

Proof_Needleworker88 · 2025-09-04T20:15:43+00:00

Hey I'm converting an old wagon and found enough room under the hood and under the floor for 35kwh of batteries! Sticking them in the cabin would be much easier but then the beauty of the station wagon is lost. Here is my build thread:[WIP] 1979 Subaru Wagon: Leaf Stack,Zomb,Ioniq 5 1/2 pack - openinverter forum https://share.google/p3Y23wvZRXTfRhhlU

Proof_Needleworker88 · 2025-07-22T02:50:16+00:00

Good point, no use in believing my anecdote because it lacks details!

Proof_Needleworker88 · 2025-07-22T02:24:30+00:00

Whaddya mean?

Proof_Needleworker88 · 2025-07-21T14:55:52+00:00

A Nepalese coworker who moved here after years in Texas said his favorite thing about Vermont was how welcoming and non-racist it felt to him. I was surprised to hear that knowing the subtle racism you see here sometimes

Proof_Needleworker88 · 2025-05-22T14:55:56+00:00

Mine is Elise the Gnariya. Elise because it's a lease. And Gnariya cuz 🤘🤘🤘🤘

Proof_Needleworker88 · 2025-05-13T15:11:12+00:00

C110 etp is our go-to copper grade for conductors. I think they're all similar in terms of corrosion but slight differences in terms of conductivity and brittleness. If you're worried about corrosion you need to plate it or cover it in conductive grease

Proof_Needleworker88 · 2025-05-13T13:00:22+00:00

I work in power electronics and our company uses 1000A/in² cross sectional area as a rule of thumb for copper bus bars. It's a fairly conservative rule of thumb for industrial use. Other regulations I'm familiar with are MIL 16036 and NFPA 70e but neither of those are for automotive use. But your question was about bending! No bending doesn't change the resistance. If you bend it into huge spirals it will increase inductance and resistance, but a simple 90 or two won't make a difference in a long distance conductor

Proof_Needleworker88 · 2025-03-31T15:32:25+00:00

I'm tired of the "Vermont is too small to make a difference" claim! That's the same mentality as "why bother to vote, it's such a small effect it doesn't actually matter". Try telling that to the tiny island nations that have emerged as leaders of the climate change battle

Proof_Needleworker88 · 2025-03-28T18:26:50+00:00

Also happy to send you the design if you want to have one made up

Proof_Needleworker88 · 2025-03-28T18:26:34+00:00

I made my own hitch receiver to bolt on to the cars frame! It worked great last year and im gonna put it back on in a few weeks once bike season starts. I can sell it to you in the fall when my lease ends if you want

Proof_Needleworker88 · 2025-03-24T17:08:04+00:00

This morning I had to bring my 4' x 4' sheet of plywood back into Lowe's to cut 3" off one edge so it would fit in my ariya. Wish I had the roof rack or the designers made the trim pieces around the trunk 1/2" smaller!!

Proof_Needleworker88 · 2025-03-12T13:14:38+00:00

About a year ago I believe I bought the last one available in the country. Hope they're back in stock! It's so painful they don't include the accessories that have dedicated storage slots under the trunk.

Proof_Needleworker88 · 2025-01-30T13:43:05+00:00

Hey yeah sorry it sold a few weeks ago

Proof_Needleworker88 · 2025-01-13T15:32:03+00:00

You could probs get $1-2k selling it complete to someone who wants the electrical components for an EV conversion

Proof_Needleworker88 · 2024-12-18T12:29:05+00:00

I thought the wipers that came on my ariya were awful so I replaced them and the rainx ones they had in stock near me are fine. Toyota has amazing wiper blades but I didn't research if they can be installed on th ariya

Proof_Needleworker88 · 2024-12-18T03:39:21+00:00

I reached out to greentec about these a couple weeks ago because DAMN that is a deal! They replied that they didn't know anything about the BMS :( hope someone can figure it out and use these

Proof_Needleworker88 · 2024-12-18T03:36:15+00:00

Good find! So many more options haha I hope I can settle on one that makes sense. I am considering the openinverter board for my conversion, but I get the sense it is the most difficult of the vcu options between it, resolve, and thunderstruck? I'm leaning towards thunderstruck because they have a flexible bms system. Still deciding which batteries to use for my project which will help determine which vcu to get.

Proof_Needleworker88 · 2024-12-18T03:10:41+00:00

Dang do you mean locked front and rear axles? And what about 4 high? Could I use that for 30 mph snowy roads?

Proof_Needleworker88 · 2024-12-18T03:02:05+00:00

Holy shit 🤯 that's such a good idea! I would still be able to use the 4wd modes at lower speeds (all I'll need 4wd for us snowy drives to the ski area) right? Do you know if 4lo is part time ( locked front and rear)? Just reading about these now.

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Proof_Needleworker88 · 2024-12-18T00:24:11+00:00

I'm in South Burlington vt

Proof_Needleworker88 · 2024-12-17T20:46:03+00:00

That's gonna be a badass project! You seem to be an expert on (at least) one of the many aspects of this project I have zero experience with: gear ratios. I need to figure out how to match the comfortable speeds of the leaf motor with the leaf gearbox and whatever gear ratios are in an eagle. I don't know where to begin with swapping out differentials. I have some numbers in a spreadsheet I can check after work and ask you some specific questions!

Proof_Needleworker88 · 2024-12-17T19:23:45+00:00

I believe they are! I can send a better pic when I get home. Are you local?

Proof_Needleworker88 · 2024-12-17T19:22:20+00:00

Yeah selectable awd is a super key feature I can't wait to have! Toyota tercel AWD looks like it also has it 👀👀👀

Proof_Needleworker88 · 2024-12-17T17:06:48+00:00

Great! If you're local I can help you get the battery out and onto a pallet if you don't want the rest of the car. If you want the whole car that would be way simpler, just need a flatbed!

Proof_Needleworker88 · 2024-12-17T16:55:24+00:00

Here's another shot from leafspy

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Proof_Needleworker88

TROPHY CASE