I hope the folks on the SPEAKEV.COM Roadster forum don't mind me reposting below what Tony wrote there RE: the installation workflow but it's pretty involved. Hats off to all you DIY'rs out there taking this on
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From "CHAdeMO for Tesla Roadster, Quick Charge Power JdeMO deposits" on SPEAKEV.COM
In order of operations:
Disassembly:
1) all tools assembled, car on a lift, shipping box opened (15 min)
2) Disable high voltage at VDMS (2 min)
EXTERIOR
3) Optional - Remove passenger side rear wheel and wheel well liner (15 min, not fun to do)
4) Optional - Remove mechanical high voltage safety plug (5 min)
5) Remove rear and mid underbody panels (5 min)
6) Remove "snow dam" if equipped (??? I've never seen one)
7) Remove anti-sway bar (5 min)
8) Remove blower(s) from rear bulkhead and push rubber manifold into cavity - don't lose metal spacers (5 min)
8a) For cars with dual blowers, remove plastic blower manifold (20 minutes, scraped knuckles, words used that are not intended for small children to hear)
9) Remove wiring for TPMS, transmission control (early cars only!!!) and any other wires in the way to mount the hardware on the bulkhead (1 min)
10) Remove rear diffuser... it's easier to do this after the blowers are removed (10min)
INTERIOR
11) Remove passenger side door threshold panel, "coin" dash panel, and dash fuse block panel, and find the electric service plug (OBD2?) (15 min)
1+38 man hours estimate for disassembly (that's what Sam and I could do). You need to factor in some clean up and corroded bolts in your part of the world.
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INSTALLATION
1) Run "fish" wire and pull external low voltage harness through:
a. the frame rail
b. carefully pull through opening between body and battery with fingers
c. fish between PEM and battery
d. put through opening at JdeMO control box (where high voltage cables will also go)
e. Zip tie to brake line
Tough to estimate, but two guys with experience fishing wires would do this in (15 min)
DO NOT PLUG INTO CAR OBD2 UNTIL LAST STEP AFTER YOU HAVE CONFIRMED CAR WILL RESTART WITHOUT FAULT CODES !!!
1a) OPTIONAL FOR SINGLE BLOWER CARS - drill two mounting holes for M6 bolts in Roadster bulkhead without damaging any nearby wires (5 min)
1b) OPTIONAL - check Roadster bulkhead for irregularities from welding and grind down any high points, and paint any bare metal (10-15 min)
2) Mount JdeMO bulkhead, reinstall plastic and rubber air manifolds in their proper location, mount blower motors (10 min for everything except that plastic manifold... 15 more min just to install that)
3) Mount anti-sway bar (5 min)
4) Mount JdeMO control box using only upper right M6 bolt (so the unit will drop down on the left side to allow access to where the high voltage cables must run (5 min)
DO NOT TIGHTEN THIS BOLT WITH THE JdeMO CONTROL BOX NOT IN PROPER POSITION... YOU WILL BEND OR BREAK SOMETHING!
5) Route the high voltage cables up to the PEM (5 min)
Be sure to put the cables through the right rib, but don't yet mount the rib
6) Intall left and right ribs, left side support braces and cross braces (10 min)
DO NOT TORQUE THE BOLTS TO THEIR FINAL SETTING UNTIL EVERYTHING IS PROPERLY ASSEMBLED.
7) Install 6 remaining M6 screws to properly install JdeMO control box. It is critical that two additional M6 holes in the rib line up (5 min)
8) Install CHAdeMO (Yazaki) inlet mount assembly and use only finger tight on the 6 M6 bolts with flat washers, so that the assembly can be moved to fit rear defuser (1.5/2.0 cars) or rear facia (2.5 cars) - (5 min)
9) Install bracket for Adell clamps on rib, only used on rear facia 2.5 cars. A total of 4 M6 bolts, do not tighten (5 min)
10) Reattach wires for blower(s), TPMS, transmission control, etc (1 min)
11) Plug in low voltage external harness to JdeMO control box only (1 min)
12) Attach high voltage cables and interlock plug to PEM:
a. This is relatively easy on short PEM cars (10 min)
b. This could take an hour or two with long PEM cars, which requires very careful drilling, cutting, filing, etc. (60 - 120 min)
13) Fit rear diffuser / rear facia to CHAdeMO (Yazaki) inlet mount:
a. Rear diffuser cars - cutout screen to allow access to inlet, plus add spacer to drop down rear diffuser "wing" to be lowered ½ inch or 1 inch. (15 min)
b. For rear facia cars - cutout opening for inlet, add hinges, add Velcro latch - this is fabrication, and could take (60 min or more)
14) Reattach mid and rear underbody panels (5 min)
15) Uninhibit the high voltage, wake up car, check for faults. If no faults, turn off car, then plug-in low voltage harness in passenger footwell. Turn car on again and check for faults (5 min)
16) Test at nearby CHAdeMO station with car in Park and ON (varies)
2-4 hours for installation and fabrication, depending on car configuration and skill and speed of required fabrications.