# Chevy Bolt conversion **URL:** \ **Category:** Battery & Chargers\ **Created:** [April 3, 2018, 12:16am UTC](https://community.electricforum.com/t/chevy-bolt-conversion/13524 "2018-04-03T00:16:56Z")\ **Posts on this page:** 20\ **Page:** 3
**Author:** ![Jonathan\_Cushing](https://yyz2.discourse-cdn.com/flex030/user_avatar/community.electricforum.com/jonathan_cushing/32/2083_2.png) [@Jonathan\_Cushing](https://community.electricforum.com/u/Jonathan_Cushing)\ **Post date:** [April 7, 2018, 7:17pm UTC](https://community.electricforum.com/t/chevy-bolt-conversion/13524/42 "2018-04-07T19:17:20Z")
Did you make a wire diagram for the output off the packs. I am about to go out and start metering for that but figured it was worth asking first. ---
**Author:** ![Inwo](https://yyz2.discourse-cdn.com/flex030/user_avatar/community.electricforum.com/inwo/32/1067_2.png) [@Inwo](https://community.electricforum.com/u/Inwo)\ **Post date:** [April 7, 2018, 7:33pm UTC](https://community.electricforum.com/t/chevy-bolt-conversion/13524/43 "2018-04-07T19:33:49Z")
No short cut. I metered and tagged each with voltage reading. Remember two will be the same. Also mark each plug and socket 1-4. So you don’t get them mixed up. On bms-24t connect; 0-4-8-12-16-20-24-28-32 next plug 32-36-2x40s-44-48-52-56-60-64 next plug 64-68-72-76-80-nc-nc-nc-nc Should be right! Make sense? ---
**Author:** ![Jonathan\_Cushing](https://yyz2.discourse-cdn.com/flex030/user_avatar/community.electricforum.com/jonathan_cushing/32/2083_2.png) [@Jonathan\_Cushing](https://community.electricforum.com/u/Jonathan_Cushing)\ **Post date:** [April 7, 2018, 8:14pm UTC](https://community.electricforum.com/t/chevy-bolt-conversion/13524/44 "2018-04-07T20:14:28Z")
Yes, It does make sense. ---
**Author:** ![Inwo](https://yyz2.discourse-cdn.com/flex030/user_avatar/community.electricforum.com/inwo/32/1067_2.png) [@Inwo](https://community.electricforum.com/u/Inwo)\ **Post date:** [April 7, 2018, 10:24pm UTC](https://community.electricforum.com/t/chevy-bolt-conversion/13524/45 "2018-04-07T22:24:37Z")
Good, as every time I type it, I worry a mistake might creep in. Every other bms is is cell 0-1-2-3 all the way thru. And use keyed sockets. ☹ ---
**Author:** ![Jonathan\_Cushing](https://yyz2.discourse-cdn.com/flex030/user_avatar/community.electricforum.com/jonathan_cushing/32/2083_2.png) [@Jonathan\_Cushing](https://community.electricforum.com/u/Jonathan_Cushing)\ **Post date:** [April 7, 2018, 11:40pm UTC](https://community.electricforum.com/t/chevy-bolt-conversion/13524/46 "2018-04-07T23:40:02Z")
After a nice flooded diet ! ![IMG_20180407_131724](https://canada1.discourse-cdn.com/flex030/uploads/electricforum/original/2X/d/d185195d450cd9325adc991a7c9f3f61eabc4937.jpg) ![IMG_20180407_131729](https://canada1.discourse-cdn.com/flex030/uploads/electricforum/original/2X/b/b293e46cfae82e08dce1e34bdfabd7b0cd0a6c9c.jpg) ![IMG_20180407_131715](https://canada1.discourse-cdn.com/flex030/uploads/electricforum/original/2X/9/98d215465aba0903d104e01aefee0be3d292bac8.jpg) ---
**Author:** ![Jonathan\_Cushing](https://yyz2.discourse-cdn.com/flex030/user_avatar/community.electricforum.com/jonathan_cushing/32/2083_2.png) [@Jonathan\_Cushing](https://community.electricforum.com/u/Jonathan_Cushing)\ **Post date:** [April 7, 2018, 11:41pm UTC](https://community.electricforum.com/t/chevy-bolt-conversion/13524/47 "2018-04-07T23:41:03Z")
Prep for mounting ![IMG_20180407_140132](https://canada1.discourse-cdn.com/flex030/uploads/electricforum/original/2X/6/6d8ffd0c1d1d4f97913160417b7a39557242ccfe.jpg) ![IMG_20180407_161213](https://canada1.discourse-cdn.com/flex030/uploads/electricforum/original/2X/f/f5f1bb0f580b5ad038ea1209df54147100cf7292.jpg) ---
**Author:** ![Inwo](https://yyz2.discourse-cdn.com/flex030/user_avatar/community.electricforum.com/inwo/32/1067_2.png) [@Inwo](https://community.electricforum.com/u/Inwo)\ **Post date:** [April 9, 2018, 9:44pm UTC](https://community.electricforum.com/t/chevy-bolt-conversion/13524/48 "2018-04-09T21:44:25Z")
Perfect, did they fit? I have mine configured the same way. Oh wait, that’s the front! I see you are planning the balance leads on the same end. Makes a long run for the neutral connection, but was the best choice for me. ---
**Author:** ![Inwo](https://yyz2.discourse-cdn.com/flex030/user_avatar/community.electricforum.com/inwo/32/1067_2.png) [@Inwo](https://community.electricforum.com/u/Inwo)\ **Post date:** [April 11, 2018, 12:16am UTC](https://community.electricforum.com/t/chevy-bolt-conversion/13524/49 "2018-04-11T00:16:21Z")
More pictures? My measurements show an inch of vertical clearance between cross-members. Looks like you may have less. ![image](https://canada1.discourse-cdn.com/flex030/uploads/electricforum/original/2X/6/657e83d847c2173727ca17d6e26de31f2506317b.jpg) ---
**Author:** ![Jonathan\_Cushing](https://yyz2.discourse-cdn.com/flex030/user_avatar/community.electricforum.com/jonathan_cushing/32/2083_2.png) [@Jonathan\_Cushing](https://community.electricforum.com/u/Jonathan_Cushing)\ **Post date:** [April 11, 2018, 8:56pm UTC](https://community.electricforum.com/t/chevy-bolt-conversion/13524/51 "2018-04-11T20:56:43Z")
First battery buts up to cross bar. Second battery sits above. ---
**Author:** ![Jonathan\_Cushing](https://yyz2.discourse-cdn.com/flex030/user_avatar/community.electricforum.com/jonathan_cushing/32/2083_2.png) [@Jonathan\_Cushing](https://community.electricforum.com/u/Jonathan_Cushing)\ **Post date:** [April 11, 2018, 11:38pm UTC](https://community.electricforum.com/t/chevy-bolt-conversion/13524/52 "2018-04-11T23:38:23Z")
![IMG_20180411_163411](https://canada1.discourse-cdn.com/flex030/uploads/electricforum/original/2X/8/841b9e6064992bbd5cae995ddd07a2d440c7cdca.jpg)Circuit board had to come out. Fuses were shorted. Soldering in New leads with fuses inline. You recommended 1.5 amp right? ---
**Author:** ![Inwo](https://yyz2.discourse-cdn.com/flex030/user_avatar/community.electricforum.com/inwo/32/1067_2.png) [@Inwo](https://community.electricforum.com/u/Inwo)\ **Post date:** [April 12, 2018, 12:39am UTC](https://community.electricforum.com/t/chevy-bolt-conversion/13524/53 "2018-04-12T00:39:03Z")
That sounds right. If you find room for a full 20s pack it will cut the work in half. ![image](https://canada1.discourse-cdn.com/flex030/uploads/electricforum/original/2X/b/b02420a16d335f5f8a245de6a5053608a19026f8.jpg) ---
**Author:** ![Inwo](https://yyz2.discourse-cdn.com/flex030/user_avatar/community.electricforum.com/inwo/32/1067_2.png) [@Inwo](https://community.electricforum.com/u/Inwo)\ **Post date:** [April 12, 2018, 1:03am UTC](https://community.electricforum.com/t/chevy-bolt-conversion/13524/54 "2018-04-12T01:03:13Z")
Close enough to tease. ![image](https://canada1.discourse-cdn.com/flex030/uploads/electricforum/original/2X/0/087b7e722d1b11976616d18783503e098301908c.jpg) ---
**Author:** ![Jonathan\_Cushing](https://yyz2.discourse-cdn.com/flex030/user_avatar/community.electricforum.com/jonathan_cushing/32/2083_2.png) [@Jonathan\_Cushing](https://community.electricforum.com/u/Jonathan_Cushing)\ **Post date:** [April 12, 2018, 1:26am UTC](https://community.electricforum.com/t/chevy-bolt-conversion/13524/55 "2018-04-12T01:26:19Z")
Thought about that and some other options. The front seemed to be the best option. Minimal fab and ease of repetition should someone else want to do it. Close proximity to all connections. Decrease in any potential line loss. Most importantly put the disconnect switch where it is easy to access. ---
**Author:** ![Inwo](https://yyz2.discourse-cdn.com/flex030/user_avatar/community.electricforum.com/inwo/32/1067_2.png) [@Inwo](https://community.electricforum.com/u/Inwo)\ **Post date:** [April 12, 2018, 2:15am UTC](https://community.electricforum.com/t/chevy-bolt-conversion/13524/56 "2018-04-12T02:15:25Z")
You need the weight up front. Perfect for your setup. Good luck with the balance leads. Scary job working hot. Unless you come up with another idea. They need be soldered or some extremely high quality fuseholders. ---
**Author:** ![grantwest](https://yyz2.discourse-cdn.com/flex030/user_avatar/community.electricforum.com/grantwest/32/15_2.png) [@grantwest](https://community.electricforum.com/u/grantwest)\ **Post date:** [April 12, 2018, 3:02am UTC](https://community.electricforum.com/t/chevy-bolt-conversion/13524/57 "2018-04-12T03:02:25Z")
Wow I have totally missed this thread. It did not show up for some reason. I had to do a search to find it.??? That seems like a great option for a 2002. Adding the weight from the new lithium’s up front will help. For the newer cars the battery’s upfront is not that easy. What will the 2 Bolt Battery’s weigh? ---
**Author:** ![Jonathan\_Cushing](https://yyz2.discourse-cdn.com/flex030/user_avatar/community.electricforum.com/jonathan_cushing/32/2083_2.png) [@Jonathan\_Cushing](https://community.electricforum.com/u/Jonathan_Cushing)\ **Post date:** [April 12, 2018, 4:06am UTC](https://community.electricforum.com/t/chevy-bolt-conversion/13524/58 "2018-04-12T04:06:55Z")
approximately 64 # each still lighter than the 150 # flooded batteries that were up front. On a side note these adapters showed up from ebay. Hard to beat the cost and they lined right up. I’ll follow back on the feedback once the cart is back on the road. > **[2pc 1" Wheel Adapters | 4x4 Hub to Fit 4x114.3 Wheel 64.1 Hub | 4x4 to 4x114.3 ...](https://www.ebay.com/itm/201923138134)** > > Bolt Pattern: Convert your hub 4x4 to fit your wheel 4x114.3. Your Factory wheel studs may extend past the surface of the wheel spacers. In this case you will need to This spacer set includes open end lug nuts to secure the spacers onto your factory... ---
**Author:** ![Jonathan\_Cushing](https://yyz2.discourse-cdn.com/flex030/user_avatar/community.electricforum.com/jonathan_cushing/32/2083_2.png) [@Jonathan\_Cushing](https://community.electricforum.com/u/Jonathan_Cushing)\ **Post date:** [April 12, 2018, 4:09am UTC](https://community.electricforum.com/t/chevy-bolt-conversion/13524/59 "2018-04-12T04:09:18Z")
There is so little room on the pack even with the PCB it may be hard to squeeze a holder in there. Planning on soldering a fuse with leads in, ---
**Author:** ![grantwest](https://yyz2.discourse-cdn.com/flex030/user_avatar/community.electricforum.com/grantwest/32/15_2.png) [@grantwest](https://community.electricforum.com/u/grantwest)\ **Post date:** [April 12, 2018, 4:40am UTC](https://community.electricforum.com/t/chevy-bolt-conversion/13524/60 "2018-04-12T04:40:03Z")
The the 2 Bolt Battery’s are gonna come in at 128 Lbs and the Flooded lead acid would have been real close in weight. So I think you will real close as far as factory ride quality. Looks like they stick out a bit assuming the hood has no issues closing. Great solution for a 2002 gem cause I don’t think this would work on a newer gem. I’ll keep checking with David to see if one can some how slide into the rear section of a new style gem. ---
**Author:** ![Jonathan\_Cushing](https://yyz2.discourse-cdn.com/flex030/user_avatar/community.electricforum.com/jonathan_cushing/32/2083_2.png) [@Jonathan\_Cushing](https://community.electricforum.com/u/Jonathan_Cushing)\ **Post date:** [April 12, 2018, 11:15pm UTC](https://community.electricforum.com/t/chevy-bolt-conversion/13524/61 "2018-04-12T23:15:19Z")
I looked at the rear section. If a mount is made to elevate the pack beyond the swing axle that would be possible. ---
**Author:** ![Inwo](https://yyz2.discourse-cdn.com/flex030/user_avatar/community.electricforum.com/inwo/32/1067_2.png) [@Inwo](https://community.electricforum.com/u/Inwo)\ **Post date:** [April 13, 2018, 12:16am UTC](https://community.electricforum.com/t/chevy-bolt-conversion/13524/62 "2018-04-13T00:16:26Z")
That sounds good. So you can find 38" of room from front of the seat to back of the spat, if the platform is raised an inch or two? In an E2 the E-brake mount may be an issue. Bottom picture. I think that I’ll take the rear off of my E4 and try it. Then I can sell my 100ah Volt pack to someone. They fit in the normal battery box. These aren’t mine but show fitment. Two in middle. One on each side. ![Gem%20volt](https://canada1.discourse-cdn.com/flex030/uploads/electricforum/original/2X/5/50765e8fedfa25ca59614bbe633ec80f1f5376d1.JPG) ![IMG_0318_zpsq33lbv3k](https://canada1.discourse-cdn.com/flex030/uploads/electricforum/original/1X/1382d8269f280fcea6c649ebdcf1102c1550229e.jpg) [Previous page](https://community.electricforum.com/t/chevy-bolt-conversion/13524.md?page=2) [Next page](https://community.electricforum.com/t/chevy-bolt-conversion/13524.md?page=4)