Redesigned Battery Box (not April 1st joke)

In the last update we saw the OEM battery boxes and how the 52kWh modules fit inside them. They do fit and using a modified OEM box is a valid approach.

After spending more time with the ZE0 box, cutting out the internal mounts, dry-fitting modules, and working through the lid spacer situation with a rubber seal I realised that while it works it introduces too many variables for a production kit and making a new one may be a better approach.

Every OEM box is slightly different depending on age and condition. The internal structure has to be cut out by hand leaving nothing to mount to. You need spacers under the box (about 20mm) and between the box and lid, plus modified gaskets and mounting hardware. It’s all achievable, it just takes time.

For the full bolt-in kit though, I’ve designed a new aluminium enclosure purpose-built for the 52kWh module layout. The advantages for a production kit are straightforward:

1. Box sits at the correct height with no spacers
2. Mounting points are designed in, so there’s no cutting or fabrication required
3. Lighter than a modified steel OEM box, which offsets the heavier modules so no weight penalty
4. Dedicated provision for a CCS2 charge inlet, keeping that option open without rework
5. Every kit ships with the same box for both ZE0 and AZE0 cars

The trade-off is materials cost. Aluminium fabrication adds to the bill of materials compared to sourcing a second-hand box. But the labour saving is significant and recurring where as material cost decreases with an economy of scale.

I’m waiting on a fabrication quote now to see where the numbers land. The plan is to offer both options: the full kit with the new enclosure, and a module-only kit for selected qualified installers who want to supply a prepared OEM box.

More to come once pricing is back!

Now is the time to reach out by email of you are interested in a Leaf upgrade battery. The magic number I’m trying to hit for the basic (non-CCS2) is $250/kWh including GST installed (approximately $13k). Expecting to be able to finalise that in a week or so.