Freelander 1 Freelander EV

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I know Ali said he wants to keep the batteries accessible from the top rather from underneath, but I was looking at the freelander, and essentially there is space under the main cabin floor pan either side of the propshaft, which could be used for extra capacity.
 
Jayridium said:
I know Ali said he wants to keep the batteries accessible from the top rather from underneath, but I was looking at the freelander, and essentially there is space under the main cabin floor pan either side of the propshaft, which could be used for extra capacity.
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There's loads of room for batteries in the FL1. There's a good amount of space between the chassis rails and floor for lots of cells.

The more I think about it, the more space I find.
The thing with new EVs, is all the battery packs are below floor level, which is done to keep the weight low down, and this same thing can be done on the FL1.
 
One other advantage of keeping batteries under the floor, is if they ever decide to vent due to a fault, the gases are outside the cabin.
 
Nodge68 said:
I'm not saying you are tied to using Leaf batteries Ali, although for easy of use and charging, this would be preferable, as they're compatible with the Leaf electronics.

What I'm saying is, going by some quick measurements, and back of the envelope calculations, there's sufficient space to put over well over 24kWh of cells under the floor, but still within the confines of the removed ICE components.

This has many advantages, but the 2 main advantages are maintained interior space, and keeping the centre of gravity low. Additionally having the battery pack below the floor, will improve occupant safety, should a battery decide to go up in flames, although this is unlikely.

From my calculations, the Freelander 1 has around 220 litres of space below the floors, consisting of around 160 where the cubby box and exhaust once fitted, full width between the chassis rails, and 30 litres each side of the propshaft, in the original fuel tank location.

What batteries you choose to use in these locations is up to you, and your budget, but as a good NMC lithium cell can hold up to 700Wh of energy per litre of space, its possible to get around 150kWh of top notch lithium cells in the space available, although in reality, using second hand cells of older chemistries, you would probably on be able to install about ¼ to a ⅓ of what is theoretically possible in the available space, once the BMS and interconnections are in there too.
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The first choice of battery is a 30kWh Leaf pack followed by a 24kWh pack followed by whatever else. As you say this will make the charging and BMS side simpler but I think I can get away with using the same electronics for any pack. The cells may be slightly different as far as chemistry is concerned but should have similar Voltage, Charging and Discharging characteristics.

As for space I think you'd be shocked at how big the Leaf battery box is. I got the empty box with the Leaf and it is huge so I'm not underestimating the space required. Fitting them all under the floor is the first preference but I won't be concerned if some have to go under the bonnet or if they encroach into the boot space a little. Access, cooling and protection from elements are the priorities but I'm not ruling anything in or out.

I have to be honest in that I haven't given the batteries as much thought as I probably should have. I'm really busy with work trying to juggle several different contracts plus I'm trying avoid loosing money on stocks and shares so my poor brain is pretty overloaded right now. I think that is why I enjoyed making the motor/IRD bracket so much as it was such a distraction.
Once I have the motor and transmission fitted I'll spend a bit more time looing into the battery situation, plus the current contract which I'm working on will finish at the end of April so I may have some spare time after that.
 
Jayridium said:
Not to mention that if they decide to ignite, there is a layer of metal between the occupants and the category delta chemical fire...
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My original plan was to have the batteries accessible from the boot but with a metal lid bolted down on them and with a vent going to the outside of the cabin. This depends on the answers I get from the testers when I speak to them as they might take a very dim view of cutting anything.
In that case I'll be doing it Nodge's way. ;)
 
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Alibro said:
As for space I think you'd be shocked at how big the Leaf battery box is. I got the empty box with the Leaf and it is huge so I'm not underestimating the space required.
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The battery box is pretty large. However the standard Leaf battery box is also full of a lot of empty space, with the cells widely spaced. If space is an issue, then the cells can be packed in much more tightly than in the Leaf box. ;)
 
I just finished the last bit of welding on the bracket and gave it a coat of Rustoleom gloss black.
Hopefully tomorrow I will get the newly painted bracket fitted and take some pics.
I can't take photos of anything in the garage right now as it's shamefully dirty after all the grinding. :(
That's tomorrows job. ;)
 
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Alibro said:
I just finished the last bit of welding on the bracket and gave it a coat of Rustoleom gloss black.
Hopefully tomorrow I will get the newly painted bracket fitted and take some pics.
I can't take photos of anything in the garage right now as it's shamefully dirty after all the grinding. :(
That's tomorrows job. ;)
Click to expand...

I'm looking forward to seeing it looking beautiful Ali, and hopefully installed in the engine (or motor) bay. ;)
 
Nodge68 said:
I'm looking forward to seeing it looking beautiful Ali, and hopefully installed in the engine (or motor) bay. ;)
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Me too but have had a really heavy week so kinda knackered. The van goes through MOT tomorrow so have a bit of work for that so not looking great for getting it in the engine bay tomorrow. Maybe Sunday. ;)
 
So today I bolted on the newly painted bracket tipped the whole thing over and dragged it under the front of the car.
IMG_20210307_141423100.jpg
IMG_20210307_141848936.jpg


After a lot of faffing about I finally got it in position with the gearbox end bolted in and the tie bar secured.
IMG_20210307_170559106.jpg

IMG_20210307_171605255.jpg
IMG_20210307_171803419.jpg


I also put the Freelander engine mount on to see where we are.

IMG_20210307_171550801.jpg


So there's good news and bad news.
The good news is everything fits perfectly and it looks like it was always meant to be there.
The bad news is I think I'm going to have to forget about the Leaf motor mount for two reasons. First I don't believe it is strong enough to support the weight of the motor and the IRD plus it's probably getting more weight from the gearbox.
The second reason is the mount is too far forward so the balance is all wrong. This means I will need to pull the bracket off again and weld something to it to pick up on the Freelander bracket.
So those hours of cutting and grinding to make the bracket fit round the motor mount were pretty much a waste of time but hey ho.
At least I can now say all those of you who said the bracket was over kill were WRONG!!! :p
It's now the main support at that end so it's just as well I over built it. :)
 
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kernowsvenski said:
Looks good Ali. Looking at all that space in the engine bay, is a battery shelf there not an option?
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It may be option if I need to, putting some batteries under the bonnet may even help spread the weight front to back but don't forget I still need to fit the inverter, power steering pump, brake boost pump, High voltage junction box and possibly the HV charger but that might go at the rear.
There are probably other things I've forgotten about too
Here is another angle of the engine bay.

IMG_20210307_171325784.jpg
 
Fair point. I didn't consider the ancillary stuff.

What's the cabin heating proposals btw? I hope you're going the whole distance :cool:
 
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