Client goal
The problem to solve
Identify why the Porsche EV conversion was showing serious faults and make the vehicle safe enough for the battery system to be inspected properly.
Project case study
Porsche 911 EV Rectification and High-Voltage Isolation Fault Diagnosis
EV rectification / high-voltage diagnostics
High-voltage diagnostic and rectification work on a Porsche 911 EV conversion. The vehicle was made safe, diagnostics showed isolation faults, the battery system was safely reduced and removed, and a serious rear battery pack issue was identified.
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Vehicle / platformPorsche 911 EV conversion
Project typeEV rectification / high-voltage diagnostics
The brief
What VASS was asked to do
Carry out safe diagnostic work on the EV conversion, investigate the isolation fault, reduce the high-voltage risk and inspect the battery packs to understand the cause of the issue.
Scope of work
Defined engineering work
- Initial EV system safety assessment
- Diagnostic scan and fault review
- High-voltage PPE and safe working procedure
- Isolation fault investigation
- Battery voltage reduction by removing busbar links where appropriate
- Battery pack removal
- Rear battery pack inspection
- Findings reported to the owner
Key systems
Systems involved
- High-voltage battery packs
- HV busbars
- Isolation monitoring/fault detection
- EV diagnostic workflow
- Battery enclosure inspection
- High-voltage safe-down procedure
Engineering challenge
What needed careful resolution
- Working safely around a vehicle with suspected insulation/isolation faults
- Reducing battery voltage safely before deeper inspection
- Inspecting battery packs where water ingress and chemical damage were suspected
- Providing clear findings without continuing beyond the agreed diagnostic scope
Practical outcome
The result
The diagnostic work identified a serious issue in the rear battery pack, including signs of water ingress and damaging electrochemical reaction. Once the findings were shown to the owner, the vehicle was returned to the original workshop for further rectification.
For similar clients
What this means for another project
This project is relevant for owners of unfinished or poorly behaving EV conversions. Isolation faults should not be ignored. A structured high-voltage diagnostic process can make the vehicle safe, identify the real cause and prevent unnecessary part-swapping.
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