Taking Over the Chevy Volt Center Console

At Nutz N Voltz, we’re always looking for ways to push the Chevy Volt beyond its factory limits. The OEM software and HMI (Human-Machine Interface) were great for their time, but EV tech has advanced, and we believe Volt owners deserve more flexibility, control, and future-ready features.

That’s why we’ve designed a custom circuit board that takes over the center console display, giving us the ability to run a KHADAS VIM3 single board computer alongside the stock Volt HMI. With this setup, drivers will be able to switch between the factory system and our custom interface seamlessly.

What’s Next

Right now, the hardware is in place and testing has begun. Our next milestone will be refining the software environment, building the switching logic between the OEM interface and the KHADAS platform, and laying out the roadmap for the first custom applications.

This is just the beginning, but it marks a major milestone for the project — shaping the Volt into a platform that evolves with its drivers, not one locked to 2010-era software.

Stay tuned as we share progress updates, demos, and eventually, a look at the new custom UI in action.

One of the most challenging — and exciting — parts of building our new replacement battery pack for the Chevy Volt is creating the high-voltage connector system that bridges our battery to the Volt’s existing wiring and control modules. While it might seem like “just a plug,” this component plays a critical role in performance, safety, and long-term reliability.

Why We Need a New Connector

The original Chevy Volt battery connector is purpose-built for GM’s pack layout and module design. Since our pack uses a different cell configuration — 18650 cells arranged in modules — we can’t simply re-use the OEM connector without major compromises.

We need:

• Electrical compatibility with the Volt’s Battery Energy Control Module (BECM) and High Voltage Powertrain Control Module 2 (HPCM2).
• Mechanical security so the connector locks firmly but can be serviced if necessary.
• Weatherproofing to protect against corrosion and moisture.
• High current handling to safely manage the pack’s peak discharge rates.

Our Design Process

We started with the OEM connector footprint to ensure plug-and-play compatibility with the Volt’s harness. From there, we modeled a new housing in CAD, focusing on:

1. Pin layout & load capacity – ensuring each contact is rated above the Volt’s maximum current draw.
2. Sealing surfaces – integrating silicone O-rings and gaskets to keep out dust and moisture.
3. Strain relief – so cable movement doesn’t stress solder joints or crimp points.
4. Heat management – using copper alloy contacts with gold plating for low resistance and better thermal performance.

Materials & Prototyping

We’re using:

• Glass-filled nylon for the connector housing (high strength, heat-resistant).
• Marine-grade copper contacts plated in gold for conductivity and corrosion resistance.
• EPDM rubber gaskets for weather sealing.

The prototype housings are being 3D printed for test fits, while contact pins are CNC-machined. This allows us to refine tolerances before moving to injection molding.

Testing & Validation

Before we roll out the production connector, we’ll test for:

• Vibration resistance – simulating road conditions.
• Thermal cycling – ensuring no cracks or loosening over time.
• Electrical load – confirming it can handle sustained and peak amperage safely.
• Ingress protection – targeting IP67 water/dust resistance.

Why This Matters

This connector is the bridge between our modernized battery pack and the Volt’s proven powertrain. By designing it to meet — or exceed — OEM specs, we’re ensuring that owners can confidently upgrade to our replacement pack without sacrificing performance, safety, or serviceability.

As we finalize the design, we’ll share more photos and possibly a behind-the-scenes look at the CAD models and test rigs.

The test Volt is coming along nicely! seats and carpet are out and I am about to cut the hump out and reinstall the battery plate so we can build this battery from the top and keep an eye on it and monitor it while we test it! There's about 50 or more lbs. of sound deadener on that floor they used a lot!

Laser Cutting & 3D Printing of the Battery Case Is Under Way!

Big news — the 3D printing of our custom Chevy Volt replacement battery case is in full swing, and if all goes according to plan, it may be shipping to us as early as Wednesday! This is a major step toward completing our prototype pack for Volt and Cadillac ELR owners.

Why This Case Matters

Our new battery pack design uses 18650 cells in nine modules, arranged differently from the OEM pack. That means we needed a completely new case to:

Combining Laser Cutting & 3D Printing

The case isn’t just 3D printed. We’re combining laser-cut metal components for strength and 3D printed structural pieces for precision fit and complex geometry.

• Laser Cutting:
• The base plate, mounting points, and reinforcement ribs are laser-cut from aluminum for light weight and durability. Laser cutting gives us:
• Tight tolerances
• Clean edges without post-processing
• Consistent repeatability for future production runs
• 3D Printing:
• The cell holders, wiring channels, and case panels are being printed in glass-filled nylon — a material that’s lightweight, strong, and heat-resistant. 3D printing lets us:
• Rapidly prototype changes
• Create custom cable routing features
• Build complex shapes that can’t be machined easily

From CAD to Reality

The case was modeled entirely in CAD, then split into sections for printing and cutting. The design process involved:

1. Thermal simulations to ensure proper cooling
2. Finite element analysis to predict strength under load
3. Alignment features so assembly is foolproof

After printing, the panels will be cleaned, heat-treated for added strength, and bonded to the laser-cut framework.

What’s Next

Once the case arrives this week, we’ll:

• Test-fit all cell modules
• Install the new high-voltage connector we just designed
• Begin final assembly of the prototype pack

This hybrid fabrication approach — combining laser-cut precision with 3D printing flexibility — ensures our battery case will be both strong enough for daily driving and custom-fit for our upgraded design.