1975 Mazda Bongo Meets 2012 Nissan Leaf

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Overcome by the need to write down about electrical automotive conversions after a current dialog with Graeme from OZDIY, I shared my curiosity with Fb and acquired a number of beneficiant presents 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 know. Ra writes:

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

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

After fairly a little bit of trawling on trade me NZMiriam discovered one thing known as a Mazda Bongo. I assumed it was so ugly that she should be taking the piss (making enjoyable of me). However no, she thought it was cool. Some analysis confirmed it was meant to be a van, though it appeared in regards to the dimension of a chilly-bin (cool field to place your beers in). Extra analysis confirmed that Japanese individuals 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 right down to Christchurch and pulled the Leaf aside in Miriam’s brother’s driveway. All of the helpful bits have 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 most likely ought to have put more cash into the recipient car. We might have spent about $NZ 3,000 for miscellaneous elements and refurbishments.

The conversion itself went pretty properly. We made contact with one of many few Low Quantity Automobile certifiers for electrical conversions within the nation, and talked by means of the conversion plan. The battery modules have 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 outdated 1000cc engine was given to our god(much less) daughter so she might 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 doable. A RippleTech REV controller was used as the principle car management unit: this enables configuration of drive profiles and handles communication with the Leaf parts so the automotive drives and expenses. Boyd Benton, who additionally labored on the venture, tells me: I’ve been concerned in creating the RippleTech aftermarket controller, this enables transplanting the Nissan Leaf drive gear into different issues, largely within the tourism trade.

One of many certification challenges is braking efficiency. Three consecutive assessments must be accomplished in two minutes, and every one requires stopping in 4.4 seconds from 100 kph. With all spherical drum brakes the sneakers, drums and brake traces wanted to be excellent. 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 obtained an enormous fail and a protracted to-do record. The massive fails have been worn operating gear (suspension and steering) and a few corrosion. This was partly as a result of our misunderstanding of the LVVTA certification course of: we must always have tried to get a Warrant of Health first, and obtained issues to the stage the place we solely failed on the truth that it was a modified car. I assume 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 by means of with the certifier first.

As soon as the operating gear was rebuilt, on the second go to we acquired 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 day by day use for espresso deliveries, boating, and browsing journeys. There are solely 2 seats, so on the open highway we’re restricted to 2 individuals 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 actually 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 seek out individuals taking photographs of it and asking “what is this?” The electrical side continues to be a buzz, as it’s unusual for older automobiles to be electrical. When individuals drive it they grow to be WAY extra excited in regards to the electrical facet of it — the one-pedal driving and actually quick acceleration make it nice enjoyable. Curiously, Mazda showed an electric version again in 1968.

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