There are some great suppliers out there when it comes to EV conversions and general MX-5 modifications. We are really lucky to have G19 Engineering very close by too. Doug at G19 sells a range of parts to upgrade MX-5s and he’s done a custom modification on our old automatic pedal box, to mount to our Tesla iBooster. He has then strengthened it and added two-position mounts for the MX-5 mk 3 digital throttle pedal, which will work perfectly with our Thunderstruck VCU. The whole thing has then been zinc plated.
Doug also supplied a second-hand mk 3 throttle pedal and new connector for it. Stuff like this makes our conversion look much more professional and saves us a whole heap of time in the process.
Without the weight of the batteries and motor in place, it is hard to be sure how it will end up but, right now the steering feels super direct, very easy and there is no stiction at all. It should weight up nicely when the car is complete.
Sorry for the lack of updates. It has been a very busy time! The complete rewiring of the MX-5e is taking a lot longer than we planned but, I’m really enjoying it We are now on the home straight and have started testing stuff.
We have all the fuse boxes installed and most of the low voltage wiring in place. We under the bonnet and inside the boot complete and are just doing the final parts behind the dash. We have a carefully colour coded loom, to simplify diagnostics and testing. Things now working include all the lights, including the winking heading lights, entertainments and navigation, charging system, electric windows, central locking, etc.
My job tomorrow is to test the heated seats. We can then put the main cabin carpet back in.
3D printed a switch plate to sit where the automatic gear level was before. The DCU in going to sit in the space underneath this and these switches allow the driver to easily select the mode (forward, neutral and reverse) + the driving mode (eco, normal, sport and race). The driving modes allow each driver to customise the regenerative braking and a few other things, to personalise the driving experience. The driver selection is fully automatic and uses BLE tags.
The thing in front of this is a wireless phone charger and holder, also a 3D printed prototype.
Designed a compact logic board using diodes for the pop-up headlights. These allow both to operate via the headlight switch and the tombstone switch, along with independent control of left and right sides using ‘wink’ switches on the dash. 3D printed a suitable enclosure and this will be ‘potted’ using a potting compound.
I don’t want an aerial on the rear wing to disrupt the smooth lines, so I’m mounting this invisible aerial on the underside of the dash. It works really well!
Picked up the vinyl graphics for the visual indicators for the driving mode (forward, neutral, reverse) and driving profile (eco, normal, sport, race). This switch plate sits in the hole where the automatic gear selector was. The vinyly graphics are stuck to underside to acrylic squares (hence they are reversed) and back-lit using addressable RGB LEDs. Going to tests out different colours to see what works best. Brightness will adapt intelligently based on an ambient light-level sensor.
Yes, it is fairly easy to do. These are only PLA prototypes. The used parts will be printed in ABS using an online 3D print service as my printer doesn’t do ABS very well. I’ve got another big project underway to extend our house though and once my new study is ready, I’ll be upgrading my 3D printer
This is our “test dash”, the original tan one that we have painted black and which also had quite a few marks on it from where things had been stuck and drilled by the previous owner(s). We have a “new” black one from Suffolk Mazda that is in excellent contion and this will be going in the car to start with.
The plan is to get the whole of the interior redone, once the car is registered as an EV. Probably in an alcantara finish with a few carbon fibre parts. This is not a priority though.
Second part of the build story is published in the MX-5 Owners Club magazine this month, called Soft Top Hard Top.
Getting very close to finishing the MX-5e rewiring project. Now have the modified fan controls and fan working as required. Made a minor mod to the fan switch, so that the air con button contrls the 3kW/400V PTC heater The logic was already in the switch to ensure that it only comes on when the fan is on.
I’ve managed to squeeze the PTC heater into the refurbished heater matrix and that will go back in next week. Then the carpets and seats can go back in!
Fitted this aluminium washer fluid tank this week too. This means the old tank can go, freeing up more space for the inverter in the engine bay.
Very close to completing the rewiring Last few bits now. Before I can test the braking system, I need to finish the plumbing with new Kunifer pipes and fittings. I’m re-using the old bias adjuster.
The iBooster connector kit can with moisture seals, crimp terminals, etc. It has a permanenet power supply and a switch power supply. 4 wires from the position sensor to the main body. Will test it very soon.
We are now on the home straight and have started testing stuff.
