Gen 2 Prius Plugin Conversion - Fuel Economy, Hypermiling, EcoModding News and Forum

evric · 12-10-2014, 05:28 PM

I am converting a 2008 Australian Prius.
I am progressing through the stages of getting this conversion completed - hopefully soon.
1/ Purchased the Plugin Supply kit (front box, rear box and contactor box)
2/ Wired to the existing EV switch wiring - yes the switch is already there in Australian Prii.
3/ Wired to the Prius Battery pack ready for connection to the contaor box.
4/ Constructed a battery frame with steel angle (20 x 20 x 3mm)
The battery frame is designed to hold 76 40Ah Winston cells
5/ Installed the 240V mains inlet on the rear bumper.
6/ Designed the charger mounting bracket for the real left position - this is being bent and holes being cut at the moment.
Jobs left to do...
a/ Mount the charger (2KW TC Charger)
b/ Change the rear springs to heavy duty variety.
c/ Wire up everything.

See the blog at www.evplus.com.au

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Have a great Christmas...
Eric

Daox · 12-10-2014, 05:39 PM

Looks like a great project. Be sure to keep us up to date.

Cobb · 12-10-2014, 07:20 PM

Those arent those MOTT cells are they? Those were troublesome for Enginer.

What about a BMS?

evric · 12-10-2014, 07:30 PM

Hi Cobb,

The cells are Winston WB-LYP40AHA LiYFePO4 cells. (Y=Yttrium)

I have ready, the 76 BMS modules from EV Power (Western Australia).
These connect to the rear box to protect against overcharging and over discharging.
I am also going to have a JLD404 in the BMS loop to turn off the add on system when the cells get below a pre-determined Ah limit- eg 8Ah.

Cobb · 12-10-2014, 09:30 PM

How are you going to take advantage of the charge? Are you going to interrupt the fuel pump fuse so the car trips into limp mode and run electric only or just drive it normally?

evric · 12-11-2014, 12:22 AM

The Plugin Supply (10KWh) kit does all that for me. The front box connects to the OBD2 port under the steering wheel and tricks the car computer into thinking the battery is fully charged so makes maximum use of the battery. Also the front box has a switch that, when pressed, disables the petrol engine. This can only be used on the flat and around 60km/hr and under. Checkout the Plugin Supply website.