1975 Mazda Bongo Meets 2012 Nissan Leaf

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Overcome by the need to jot down about electrical automotive conversions after a latest dialog with Graeme from OZDIY, I shared my curiosity with Fb and obtained a number of beneficiant provides of story. Right here is one, written by Ra Cleave and Boyd Benton of New Zealand, with some slight edits by me, to make it simpler for foreigners to grasp. Ra writes:

Boyd requested me to ship a wee writeup concerning the 1975 Bongo Van that we transformed. Be at liberty to make use of bits and items or the entire of this, and in case you have some other questions, simply sing out.

My accomplice Miriam is a espresso roaster who delivers espresso round Rotorua by e-bike. Some supply days had been getting a bit huge for the cargo bike, and so Miriam began on the lookout for an electrical automotive or van. New choices had been few, costly, and never “iconic” in any respect. I’d accomplished an EV conversion with my pal Boyd and so we began occupied with changing one thing “old-fashioned.”

After fairly a little bit of trawling on commerce me NZ, Miriam discovered one thing known as a Mazda Bongo. I assumed it was so ugly that she should be taking the piss [making fun of me]. However no, she thought it was cool. Some analysis confirmed it was meant to be a van, though it appeared concerning the dimension of a chilly-bin [cool box to put your beers in]. Extra analysis confirmed that Japanese folks now name their elders “Bongo” (in the event that they like them).

The Bongo was in Christchurch [800 km away], and we discovered a pranged Nissan Leaf going on the Christchurch public sale home. So, we flew all the way down to Christchurch and pulled the Leaf aside in Miriam’s brother’s driveway. All of the helpful bits had been squished into the poor wee [small] Bongo, and we travelled up nation to Rotorua at 70 kph. We rolled into Rotovegas at about 2am on a Monday morning, after utilizing about 5 litres of oil and 10 litres of cooling water!

We spent $NZ 4,400 on the Leaf, and $NZ 15,000 on the Bongo. The Bongo appeared bloody costly on the time, however Covid-19 had elevated second hand automotive costs and looking out again we in all probability ought to have put extra money into the recipient automobile. We might have spent about $NZ 3,000 for miscellaneous elements and refurbishments.

The conversion itself went pretty nicely. We made contact with one of many few Low Quantity Car certifiers for electrical conversions within the nation, and talked via the conversion plan. The battery modules had been bolted down within the cargo space of the Bongo, and the electrical motor, inverter, junction field and onboard charger all match into the rear engine bay. The poor previous 1000cc engine was given to our god(much less) daughter so she may pull it aside.

To make certification smoother, we didn’t minimize any of the excessive voltage cabling, and reused as a lot of the Nissan electrical drive parts as attainable. A RippleTech REV controller was used as the primary automobile management unit: this permits configuration of drive profiles and handles communication with the Leaf parts so the automotive drives and prices. Boyd Benton, who additionally labored on the venture, tells me: I’ve been concerned in creating the RippleTech aftermarket controller, this permits transplanting the Nissan Leaf drive gear into different issues, largely within the tourism trade.

One of many certification challenges is braking efficiency. Three consecutive exams need to be accomplished in two minutes, and each requires stopping in 4.4 seconds from 100 kph. With all spherical drum brakes the footwear, drums and brake traces wanted to be good. Fortunately Australian suppliers nonetheless had shares of Bongo brake pads! The Mazda Bongo was extra widespread in Australia than New Zealand.

The primary go to to the certifier received a giant fail and an extended to-do listing. The large fails had been worn working gear (suspension and steering) and a few corrosion. This was partly on account of our misunderstanding of the LVVTA certification course of: we should always have tried to get a Warrant of Health first, and received issues to the stage the place we solely failed on the truth that it was a modified automobile. I suppose every nation may have totally different procedures for this. We had the electrical conversion facet of issues just about proper, as we’d talked issues via with the certifier first.

As soon as the working gear was rebuilt, on the second go to we obtained the “OK” to be used on New Zealand roads! Then it was off to the signal author and since then the Bongo has been in virtually each day use for espresso deliveries, boating, and browsing journeys. There are solely 2 seats, so on the open highway we’re restricted to 2 folks and 2-3 boards. We’ve got had three mountain bikes on a rack, 3 riders and 1 driver, however that was on forestry roads going gradual!

It’s definitely able to pulling bigger hundreds, because the low-speed torque is a lot larger. However with the additional weight (primarily because of the battery) the allowed carrying capability has been decreased in comparison with the unique: it was 500kg however is now solely 250kg.

Folks love the van. Miriam typically comes again to the place it’s parked to search out folks taking pictures of it and asking “what is that this?” The electrical facet continues to be a buzz, as it’s unusual for older automobiles to be electrical. When folks drive it they develop into WAY extra excited concerning the electrical facet of it — the one-pedal driving and actually quick acceleration make it nice enjoyable. Curiously, Mazda confirmed an electrical model again in 1968. 

The 1975 Bongo Van is so small and so unusual on New Zealand roads that it attracts heaps of consideration. Additionally it is tremendous enjoyable to drive, with heaps of torque and that one-pedal EV really feel. The whole value was about $NZ 22,400 and I’m undecided what number of hours of free labour. So, although it took extra time and cash than we anticipated, it (now) appears completely value it!