Chademo semi-compatible dummy plug - for testing by qualified persons only

thingiverse

WARNING: Handling these files wrongly is your own fault. I won't hold anything against you even if you somehow manage to mess up with 400V. Don't say I didn't warn you about the District 9 explosion. This project isn't responsible for your foolishness. I made my own version after being frustrated by the $3000 price tag. Prices can drop to around $2500 if you buy in bulk. The files were created with Blender, and repaired using NetFab Studio Basic. The purpose of this project is experimentation, not commercial production. It's not designed for water-tightness or durability under heavy loads. Safety enthusiasts need not apply. Collaborate with the community by visiting http://www.mynissanleaf.com/viewtopic.php?f=44&t=13349 to share your ideas and experiences. This 3D printed parts project focuses on experimentation and development, not commercial production. A portable, isolated charger capable of 17-20kw is the goal. Canada's longest green highway has J1772 charging stations for free along the Trans-Canada Highway, which is impractical without a portable Chademo. You could also use two separate 240V 50A connections (like at an RV park) with the right inputs. Please follow these safety rules when using this charger: 1. Do not touch any plug/cable while the charger is running. 2. Avoid using the charger in wet or moist conditions (liquid or solid). 3. Abort the charge if any power pin temperature reaches 50 degrees Celsius (hot to the touch, but no risk of melting ABS plastic). 4. Do not leave the charger unattended. If curious and uninformed people are near the car, abort the charge. 5. Remember rule 1! Credit goes to MAKERFAM for the pistol-grip thing (part number: 121658). For rubberband gun pieces, print with support and ensure your machine is calibrated accurately. The handles will need rotation as they barely fit a Reprap Prusa Mendel print bed. Print ABS sections with a layer thickness of 0.3mm, and PLA parts with a 0.4mm layer thickness (different nozzle). To print the plug, drill holes for pins with a 23/64" bit for the 9mm holes and a 7/64" bit for data pin holes. Assemble with 8-32 nuts and screws of varying lengths. Use 1.5mm pins from this link: https://1drv.ms/u/s!Ah-wSazeIk6il1uwUCFKNesYAciV?e=4EBhFp, 9mm power pins from this link: https://1drv.ms/u/s!Ah-wSazeIk6il1o7ojQ8hqimbJr_?e=BBUD0P, and the entire assembly from this link: https://1drv.ms/u/s!Ah-wSazeIk6il1yQpV3vVhzOeBR?e=4ZLSuz Follow these safety rules when using the charger: 1. Do not touch any plug/cable while the charger is running. 2. Avoid using the charger in wet or moist conditions (liquid or solid). 3. Abort the charge if any power pin temperature reaches 50 degrees Celsius (no risk of melting ABS plastic). 4. Do not leave the charger unattended. If curious and uninformed people are near the car, abort the charge. 5. Remember rule 1!