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.


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

Volt Meter
Electrical Tape
Knife/stripping tool
Diagonal Cutters
Micro Torch/Heat Gun
<p>This looks ideal, thank you.<br><br> 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)<br><br>The 2013 and onward Nissan Leaf has the 32A charger built in but still wants to mate only with a proper EV point.<br><br>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 &pound;20 of parts (markup) and an hour's work.</p>
<p>New kits from MEMTEC ltd (memtec.co.il)</p><p>2 charging currents 16/10 Amp switch selected. Very small electronic box (130x80x70 cm)</p>
<p>Sounds good.... I was just wondering what this would cost to construct?</p>
BlackAngel999 - I'm sorry for continuing this pointless waffle and hijacking your 'ible. It won't happen again.
BlackAngel999 - I'm sorry for continuing this pointless waffle and hijacking your 'ible. It won't happen again.

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