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Looking for info on converting a gen 2 Acty to electric

Discussion in 'Honda Acty' started by Aoman, May 21, 2020.

  1. Aoman

    Aoman New Member

    Hi guys, I'm new here. I was looking for specifically information about the engine's output shaft. So the OD, the number of teeth, the ID and tooth width?

    I found some good information already about other aspects, but basically I've seen many conversions where a key'd motor sleeve is welded to a clutch splined hub and off we go. Is it that simple? does such a thing fail eventually? I remember working for a hybrid company we had problems with engine shlap on the rubber components of the motor connection.

    for example mcmaster's 6408K14 adapter.

    2nd gen Acty km/h @ RPM
    4th: 91 @ 7500
    5th: 110 @ 7500

    Another person managed to put 38 Thunder Sky LFP160, 3.20 Volt, Lithium-Ion into a similar truck
    I looked into some motors and found that in general you need to spend $800 to $3000 for a motor:

    here's a good one that has been used in other projects:

    but I see the 110km/h@7500RPM and I go... hmmm it would be nice to have a truck that can go up to 80mph so that's 128km/h. Even if you never get to use it, it would be nice.

    So anyway, what's a good /cheap strategy here?... I'm gonna tell you my little plan.
    I'm going to buy a salvaged nissan leaf and harvest its organs into the mini truck. There are some challanges that I can already see, but hey, its the cheapest way to go.

    plus I already know that the leaf's output shaft has some possible cheap spline sources.. sorry, I'm currently obsessed by the spline info.
  2. Limestone

    Limestone Active Member

    Welcome, Interesting, keep us posted, with info and pics! Good Luck!
  3. Aoman

    Aoman New Member

    Well this is going to be theoretical until I finally move. I'm in between California and Washington. But for now, I found that the Nissan Leaf motor can spin up to 12,000 rpm with its 8:1 reduction gearbox. So the gearbox has got to go. However the input gear looks awesome for a grinder/welder adapter.

    12,000 RPM plus lots of info on interface products between inverter and Android tablet with Torque app and Batteries:

    Interfacing with "open inverter"

    The lazy andwand cheap way for slow 40mph off-road/highway version

    Anyway, back to the adapter coupler:

    Looks like the leaf comes with an o-ring on the spline. This is great because I can add a sleeve with some Grease on top of the shaft. The purpose being to prevent damage to the spline over time and ofcourse perfect spline fit.

    On the Honda Acty side I would then do that the rest of the crazy people do. Basically drill a large hole in the Nissan gear, then do a heat/cold fit to install a sleeve made of the clutch spline. So I would drop that in a bucked full of dry ice, and the Nissan Leaf gear would be in a hot oil bath at 300C or better, in a food toaster. Once the temps are reached, then just drop the sleeve inside the hot gear rod and watch it clamp like crazy.
  4. Aoman

    Aoman New Member

    Here's a good idea of how that lazy and low speed version system works:

    Watch the end first.... Yahoo! Where are my homedepot plywood sheets!
  5. Aoman

    Aoman New Member

    The leaf charger weighs 60lbs, the inverter section is 33lbs, and the motor+transmission is 180lbs. This is dry, there's also some coolant. The motor is 12" high including the ugly brackets on the top, 20" long interface to rear hub, and 19" wide (width of ugly brackets).
  6. Aoman

    Aoman New Member

    Benjamin Nelson is working currently in a conversation using the Leaf system. So I'll be watching and following.

    I still have a long way to go before I end up with a house and hopefully a good garage to work in. For now, I'm just going to be gathering as much information as I can.
  7. Limestone

    Limestone Active Member

    Grandpa always said, "Son you gotta git it in yer head first"!
  8. Aoman

    Aoman New Member

    That's right. I gotta imaginate this thing. I don't even know why I want it. I just know that I will be buying a house and that in it there will be a garage and that in the garage I will have a broken down leaf and a Honda Acty with no engine in it.

    I love the look of it. I think it's awesome looking and I want one with the sole purpose of carrying 8x4 sheets of stuff from home Depot. I'm even thinking that I will add a hydraulic tailgate to make the gate 8ft long. Maybe chop the front cab in half so I can carry long 14' 4x4s on it. I can also add side carrying shelves for that. Oh it's gonna be great. I might have to buy two just in case I screw up the first.
  9. Limestone

    Limestone Active Member

    Hopes and dreams! That's what keeps us going! I like to chew on Idea's for a while, before I dive in! Oh, that's not to say I haven't dove in head first, a time or two!
  10. Limestone

    Limestone Active Member

    I have had a lot of experience with lift gates, although, never owning one, they are a great tool, as needed or required in our projects or work situations! However, you've got me thinking, and I'm sure you already thought of this. Most of these units, can weigh a lot! In regards to these mini's, added weight can be an issue, especially extended farther back, on these units! But that's half the fun, in designing and customizing your own unit, kinda personalizing it if you will! I know it can get expensive, but aluminum, comes to mind, in building the hyd. lift! With hyd. lift units expensive, any way, why not, copy/design/build your own using light weight materials? Yrs. ago I had a good friend of mine, (steel fabricator), copy some heavy duty steel ramps, on a construction carry all, trailer, for heavy equipment hauling, and he made them heavier duty out of Aluminum! Extremely light weight, (easier on my back), and they held up extremely well! Still like new when I sold it some yrs. later! I'm not sure on your skill level's, but it sounds like your not afraid to get after it! I still have a lot of ideas for mine, and I will keep pushing, and doing, until I can't! It's officially, 2 yrs. since I inherited mine, and I'm about half way to where my mind has taken me! It's been a lot of fun, and challenging at times, but that's what keeps us going! Good Luck!
  11. matt167

    matt167 Active Member

    Rich Rebuilds put a Zero motorcycle powerplant in his old hotrod. He had a motor bellhousing built that centered the motor into the transmission. I can't remember if he kept the clutch or not, but you could do it either way..
  12. Aoman

    Aoman New Member

    That's cool
    That would be awesome. I hadn't thought about using aluminum. I use aluminum at work all the time for my design. I'm surprised it didn't cross my mind. I've been looking for YouTube designs to steal ;).

    Have you seen how cheap the trucks are these days? I've seen some for like 1000 I you just go pick it up at the Tacoma port. But now I realize it's because the cars are not here yet, so you gotta wait. First thing I'm going to do is try to model up as much as I can of the truck. I'm using FreeCAD for that so I can share it with anyone else. That way others can share designs with me too.
  13. matt167

    matt167 Active Member

    Don't get too excited. The trucks would cost about $1,200 if they were being given away free in Japan. Reason is shipping is $800-1,200 depending on who you use for your sale.. The real cost will be $2,500- 3000 give or take.. If you use a dealer like Beforward they give you the exported price but you have to pay customs tax at 25% and fees for all the paperwork that needs filed, plus you might need a broker for your port
    Limestone likes this.
  14. Limestone

    Limestone Active Member

    That's good info. Matt!
  15. Aoman

    Aoman New Member

    yeah, very good to know. I'm expecting to pay around 5k for mine, but if I can get a bargain that is aesthetically OK, then I can go for that.
  16. Aoman

    Aoman New Member

    I found that openinverter has some competition or maybe its the same project:

    its either that or buy a full savaged leaf because that's the only way you will get a controller/BMS/Charger etc that will work together happily.

    but if there is no need for the fancy leaf display, I would be more than happy to buy the battery, the motor and the inverter separately and then use open inverter to control it.
  17. Limestone

    Limestone Active Member

    Sounds to me like your headed in the right direction!
  18. Aoman

    Aoman New Member

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