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Picture of DIY J1772 EVSE
To begin with this is not for the feint of heart as you will be working with 220V at possibly as much as 80A. That being said, I TAKE NO RESPONSIBILITY FOR YOU ELECTROCUTING YOURSELF. If you don't have experience with High Voltage/High Current I'd advise you not to even attempt this. (Dire warning, I know. BUT I don't want to hear about anyone earning themselves a Darwin Award for attempting this. There is too many of those these days resulting from copper theft.) 

>>>I take no responsibility for you "bricking" your car for your not wiring things properly. <<<

Designing an EVSE, or charger as some say, is a great learning experience as well as having control of the form factor make it well worth the time and trouble to make one.

>>>READ THE ENTIRE INSTRUCTABLE BEFORE YOU TRY TO BUILD THIS!!!<<<

I also assume that you know how to work safely, and how to wire things in reference to a schematic.

Step 1: Tools and Supplies

What you will need:
J1772 EVSE control board - Open EVSE project (should be in Google Code, and they have great diagrams for EVSEs.)
J1772 Plug & Cord assembly - TucsonEV
Contactor/Relay/SSR - Electrical Supply
Box - Home Depot
12v PSU - Electronics Shop
Strain Relief for J1772 cable assembly - Electrical Supply
CR Magnetics 8420-1000-G - DigiKey
Heat-shrink tubing - Electronics Shop

Tools:
Volt Meter
Drill
Taps
Screws/bolts
Electrical Tape
Knife/stripping tool
Diagonal Cutters
Micro Torch/Heat Gun
 
Guy MarkT1 month ago

This looks ideal, thank you.

I am wanting to make the unit as compact as possible though as the idea is that this sits in the boot of the car with a length of 6mm cable and a standard 32A plug on the end. At that point the car can be charged from any standard 32A outlet with RCD (aka GFCI)

The 2013 and onward Nissan Leaf has the 32A charger built in but still wants to mate only with a proper EV point.

I am amazed that there isn't a market for a compact controller with the CEE 32A plug on the end of some 6mm cable. Any electrician worth his salt can provide a 32A outlet back to the CCU for £20 of parts (markup) and an hour's work.

moshe.cal5 months ago

New kits from MEMTEC ltd (memtec.co.il)

2 charging currents 16/10 Amp switch selected. Very small electronic box (130x80x70 cm)

Cable_16-10.jpg
tfcm7 months ago

Sounds good.... I was just wondering what this would cost to construct?