Exterior Mounted 12V Magnetic Battery Charger Connector For Evoras - LotusTalk - The Lotus Cars Community
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post #1 of 17 (permalink) Old 07-01-2019, 02:36 PM Thread Starter
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Exterior Mounted 12V Magnetic Battery Charger Connector For Evoras

I recently installed an exterior mounted 12V magnetic connector for my Evora's battery tender. This is a great solution for hooking up tenders on our Evoras without having to open the hatch again. In fact, as simple as it is, I think that this is probably the best mod I've done to my car so far.

Here's some of the pros of the install:

1. No longer have to pop the hatch every time you park the car or go to take the car out (to plug/unplug battery tender).
2. If by chance the battery does go flat, you can put a tender on it so you can get 12V power to pop the hatch for a battery replacement.
3. If you forget to disconnect the tender prior to driving off, it will disengage by itself without damage.
4. Due to the magnetic coupling, no power flows through the socket terminals when it is not connected.
5. Once installed, it literally takes 2 seconds to connect/disconnect.

And here's the cons:

1. Time to install (didn't really take that long )
2. Requires that you drill one hole to mount the power socket port.

Obviously, the pros completely outweigh the cons!

As mentioned above, the only hole that I drilled was to mount the actual connector port. I could have made a bracket to mount it so that I did not have to drill a large hole in the car. However, placement of the bracket would probably have made the port more obvious. Plus, I'd still have to drill holes to mount the bracket. On my GTE rear bumper, mounting the port down low worked great for me.

Because of the mounting location I chose, I did not have to drill additional holes anywhere to get the wires down to the port. Instead, I ran the wires from the battery, around the back of the trunk and out the small vent located behind the carpet on the driver's side (there's a rubber flap on the outside of the vent). The wires easily dropped down to the port mounting location (very easy to grab with diffuser removed).

This was a very basic and easy install. And, although I installed it on my GTE rear bumper, this will also work with OEM Evora NA/S/400 bumpers. It probably can even be mounted on the side of the diffuser FINISHER (not the diffuser itself unless you were to disconnect the wiring every time you drop the diffuser). So, you just have to pick your mounting location, check to make sure the wires drop down easily enough to where you would like to place it, and verify proper clearance behind it prior to drilling.

Here are the basic steps to do the install.....

(NOTE: If you do not know how to do basic wiring on a car, please seek professional assistance or continue with the install at your own risk.)

1. Drop the rear diffuser by removing the two M8 button head bolts and the seven M8 hex head bolts. (You could also remove the left rear wheel and drop the wheel liner after removing the push pins if you would like. But, I did not do this.)

2. Remove the battery housing cover by removing the knurled knobs or thumbscrews based on your model year (on MY '10 -'11, you have to lower the rear bulkhead carpet first to get to the battery box.)

3. Loosen the plastic hatch latch striker cover by removing the two M6 nuts and one screw. Then, pull the driver's side free so that you can move the rear carpet down and see the vent area.

4. Determine and mark your power socket mounting location behind the lower left wheel area (after verifying there is no obstruction and enough clearance behind it) and drill a hole using a 1-1/8" / 29MM hole saw.

5. Preliminarily run your wires (using the appropriate gauge based on your tender) from the battery box to the lower hole by going around the trunk on the driver's side (under the carpet) and out the cabin ventilation vent located at the rear of the trunk on the driver's side (there is a rubber flap on the vent that allows the wire to easily pass through- run the wire in the vent corner so the flap still covers most of the vent.) Then, go under the vehicle and reach up in the lower fender area to grab the wire.

6. While in the lower fender area, slide the socket port connector's large plastic nut over the wires, then feed the wires through the mounting hole you drilled. I also used Painless Wiring PowerBraid Split Braid Sleeving over the wires for added protection.

7. Terminate your wires at the magnetic socket connector's mount using female spade crimp connectors. Pay attention to proper +/- polarity as marked on the mount. Use heat shrink tubing over the female spade terminals. After pushing the spade terminals onto the connector, push the connector into the hole and secure with the large plastic nut (you previously fed the wires through) from within the lower fender.

8. At the battery box end, add an appropriately rated in-line fuse (based on your tender) on the pos/+ lead. Then, terminate your wires at the battery box using ring connectors while again paying attention to proper +/- polarity. Check your wiring one last time prior to fastening the wires to the battery terminals.

(NOTE: YOU SHOULD NOT HAVE TO COMPLETELY REMOVE THE BATTERY CABLES TO INSTALL THE RING CONNECTORS, THUS AVOIDING TRIPPING THE AIRBAG LIGHT. HOWEVER, AS A PRECAUTION, DO NOT ATTEMPT THE BATTERY HOOK UP WITHOUT WAITING AT LEAST 30 MINUTES AFTER SHUTTING DOWN THE CAR AND REMOVING THE KEY TO ALLOW THE VARIOUS SYSTEMS TO SHUT DOWN IN THE APPROPRIATE SEQUENCE.)

9. Wire the plug end of the magnetic connector to your battery tender while paying attention to proper +/- polarity and finish assembly of the connector.

10. Attach the magnetic connector to the port to test. Most modern tenders will indicate if there is a polarity issue.

11. If everything is working correctly, put the diffuser, battery cover, carpet and plastic hatch latch striker cover you loosened back in place. (If you removed the rear wheel, re-install rear wheel/wheel liner and properly torque the bolts.)

The best part about this connector is that Sherman at HethelSport just put together a comprehensive installation kit that works with the popular battery tenders. He supplies all of the necessary connectors, wiring, wiring cover, fuses, PLUS a pre-wired cable adapter for your brand of tender which makes the installation even easier. He even goes one step further by adding an optional secondary fuse in case you want further battery protection.

You can order the kit at: Battery Charger Connection Kit | HethelSport
or contact Sherman at [email protected] for additional information.


Now you can enjoy charging without popping your hatch.
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post #2 of 17 (permalink) Old 07-01-2019, 02:48 PM Thread Starter
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Oh... and after my brother saw my install, he wanted one on his Porsche too.....
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post #3 of 17 (permalink) Old 07-01-2019, 03:31 PM
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Nicely done, and great write-up. I cringe at the thought of drilling through that carbon fiber though!

I'll probably grab one of these kits from Sherman in the near future, although I think I'd prefer if I had a wireless charging mat I could just park over
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2011 Evora NA - Phantom Black | Paprika | MT | 2+.5
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post #4 of 17 (permalink) Old 07-02-2019, 04:25 AM
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Very cool; takes care of a number of potential problems with battery failure, affords piece of mind.........

"the most uninterested man in the world....stay thirsty, my friend"
2017 Evora 400
2012 Evora S-sold
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post #5 of 17 (permalink) Old 07-02-2019, 05:09 AM
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I used the same parts, plus a 3D printed part from Thingiverse, to allow me to mount the assembly on the rear license plate. No holes to drill: the battery charging wires went through the same hole as the wires to light up the license plate. I'm pretty sure that I learned about this approach in another thread on this site.

https://www.thingiverse.com/thing:2473931

Happy to print these for anyone who wants one
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post #6 of 17 (permalink) Old 07-02-2019, 05:13 AM Thread Starter
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Quote:
Originally Posted by jon_bondy View Post
I used the same parts, plus a 3D printed part from Thingiverse, to allow me to mount the assembly on the rear license plate. No holes to drill: the battery charging wires went through the same hole as the wires to light up the license plate. I'm pretty sure that I learned about this approach in another thread on this site.

https://www.thingiverse.com/thing:2473931

Happy to print these for anyone who wants one
I saw that thread a while ago. I'm pretty sure it was for Elise/Exige where running the wire to the bumper/plate area is much easier.

How did you get the wire down to the plate area on the Evora without removing the bumper? And didn't it block your reverse cam mounted there?
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Last edited by 2011 chrome orange; 07-02-2019 at 08:01 AM.
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post #7 of 17 (permalink) Old 07-04-2019, 04:21 PM
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How long does it take for the battery to die if not plugged in?
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post #8 of 17 (permalink) Old 08-18-2019, 04:57 AM
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This looks like a great solution. I am not keen on drilling a hole in the diffuser on my Evora 400. Has anyone does this with an alternative less traumatic location for the power socket?
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post #9 of 17 (permalink) Old 08-20-2019, 05:21 AM
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Quote:
Originally Posted by am143a View Post
This looks like a great solution. I am not keen on drilling a hole in the diffuser on my Evora 400. Has anyone does this with an alternative less traumatic location for the power socket?
too bad under the gas cap is a bad idea for other reasons...
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post #10 of 17 (permalink) Old 08-20-2019, 07:45 AM Thread Starter
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I don't have a 400 in front of me to in order to suggest an alternate mounting location. But, I'm sure there is somewhere in the rear that it would still work without drilling the larger hole. Worse case for mounting would be that you have to make up a simple bracket.

I'd love to hear back from jon_bondy on how he ran the wires without removing the rear bumper while mounting his 3D printed assembly on the rear license plate of an Evora??
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post #11 of 17 (permalink) Old 08-20-2019, 12:05 PM
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I put my 400 on my lift over the weekend and once you get underneath there are plenty of options. I will probably make a bracket and install it using one of the existing bolts. If/when I am happy with whatever I end up doing I will post a pic or two here. Thanks.
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post #12 of 17 (permalink) Old 08-20-2019, 12:22 PM
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Great writeup, Chromy, and a very nice idea for our cars. #3 on the "pros" list is not to be underestimated. (Someone who says he hasn't done that is either a dewy youth or an experienced liar.)
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post #13 of 17 (permalink) Old 08-21-2019, 04:06 AM
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Quote:
Originally Posted by 2011 chrome orange View Post
I'd love to hear back from jon_bondy on how he ran the wires without removing the rear bumper while mounting his 3D printed assembly on the rear license plate of an Evora??

I installed my magnetic tender connection on the back of an Elise, not an Evora. That said, the situation seems similar. One would have to remove the plastic part on the inside of the rear of the trunk in order to get access to the part of the body that is behind the license plate. There is a light above the plate, so there must be a hole in the body for the wires to pass through. You just add another pair going through the hole. Maybe someone who has disassembled that part of an Evora can comment further.

I love the magnetic tender connection for my Elise, and have considered adding that to my Evora
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post #14 of 17 (permalink) Old 08-21-2019, 11:25 AM Thread Starter
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I have had my rear bumper off (as depicted below). And, although anything is possible, I did not see an easy way to run the wires to the license plate area without removing the bumper again. Also, a license plate mounted plug connection would have certainly interfered with/obscured my rear camera.

If you decide to add one to your Evora, please let us know how you run the wires. It would be great to be able to easily mount it to the plate area.
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post #15 of 17 (permalink) Old 08-22-2019, 08:54 AM
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Thanks for the photo. I agree that the Elise is much simpler to implement than the Evora. The Elise has a single central through hole with neither the bumper nor the interior plastic part that are present for the Evora. It should be possible to do, it will just require more time removing and reinstalling the two above parts.
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post #16 of 17 (permalink) Old 08-31-2019, 10:10 AM
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HethelSport external battery charger kit installation.

This is a simple but very useful mod. The kit from Sherman at HethelSport is first rate and put together with obvious care and attention to detail.

I was not ready to drill a hole in my bodywork, so I made a bracket out of some aluminum and mounted that behind the diffuser on the driverís side. The bracket is bent up slightly so that the charger port is parallel with the road.

I ran the wire through the hole for the battery breather tube- this is on the left side of the battery area. I was able to push both the wire and the tube through the grommet and then reinstall the grommet in the hole with the aid of a little silicone grease. I used a piece of coat hanger wire to guide the charger wire through the hole into the back of the wheel well and zip tied the wire to the bracket that connects the diffuser to the rear subframe. I used some shrink wrap on the end of the wire sleeve to tidy things up.

Overall, I am extremely pleased with how this turned out.
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post #17 of 17 (permalink) Old 08-31-2019, 12:24 PM Thread Starter
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Looks like a great alternative way to mount it. Nice job!
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