Handling the POWER

[RegularGuy]

I've officially begun the switch to electric on my 2007 FX4 lvl2 ranger. Politics aside, it appears to be the correct choice for my use case, and after approximately 4 years, I should have made my money back in fuel.

Starting out, I'm doing a number of modifications which won't mess with the factory drivetrain. Full length skid plates (constructed out of thin stainless sheets), converting the power steering, brake booster, and radiator fan to electric. Last on the list, is converting the AC to electric. A water pump conversion in this case, doesn't make sense.

A small number of questions remain however. Eliminating the engine and transmission, would the transfercase then be the weakest link?
A 400kw motor puts it equivalent to having a stock engine that's always in first gear, a more powerful motor however, is of negligent price difference.... Even so. I'm not so sure I'd want something that powerful

 

[SenorNoob]

Sounds like a sweet project. Take LOTS of pictures please.

What do you mean by stock engine always in first gear? (I'm only vaguely familiar with electric cars.)

 

[rumblecloud]

Very interesting project. Absolutely will follow this string.
Yes lots of pics and detailed log - which I am sure you will keep regardless.

 

[ericbphoto]

Are you going full electric? Or hybrid? Sounds like hybrid, since you mention radiator fan and water pump.

 

[Eddo Rogue]

I would say go "one size up" on the motor power. Its one of those better to have and not need situations. Also the actual power output may vary, depending on battery charge/life, drivetrain, friction etc...

I am not sure about the transfer case, but you might want to swap in something beefier than stock while you have it gutted.

You might know this, but there's a TV show called "Vintage Voltage" where they convert classic cars to electric for customers. Its based in the UK I think. Anyways, it seems they leave the drivetrain mostly stock on most of the vehicles, and just run em im 2nd or 3rd gear.

 

[RegularGuy]

What do you mean by stock engine always in first gear? (I'm only vaguely familiar with electric cars.)

The factory 4.0 sohc makes 207 hp, with a 1st gear ratio of 2.47:1 the electric motor will require a minimum of 511 hp (400kw as electric motors are rated in kw) in order to produce the same torque.

Are you going full electric? Or hybrid? Sounds like hybrid, since you mention radiator fan and water pump.

It will be a full electric, a 300 mile range appears to be a conservative number for the build as I'll be using only a single motor for a less aerodynamic vehicle (comparing to the awd model Y) but with only a single electric motor.

One of the biggest things to calculate will be final curb weight. The truck has an already questionable payload capacity, currently sitting around 4200lbs curb weight. That leaves just under 1200lbs of payload with the factory drivetrain.

The timing of the project is in response to tesla's announcement of their new 4680 cells which should make the used market battery packs substantially more affordable. There are also a few other options for batteries but in my case, the biggest limiting factor for this build is going to be weight. Preferably, the conversion would actually reduce the curb weight. This is unlikely however as the primary weight reductions will be the engine, transmission, fuel tank, and exhaust; the weight of which is more than offset by the weight of the battery alone.

 

[ericbphoto]

If it's all electric, why were you talking about radiator fan and water pump? Or will your inverters be water cooled?

 

[bobbywalter]

Still going to be some time for me....but I too have been waiting for this opportunity with the battery market. These will easily allow me to construct massive portable pv power.....at the price I can afford...

T case is a non issue.


Adding a leaf will solve your payload weight....which is also a non issue regardless...


The brakes are good for an extra 3 k in trailer pushing it down the road.



Now...for me.

I have a slightly different approach for my rig, you may possibly consider.

Flately. Hybrid. No way I would limit options doing a conversion. Redundancy is my general goal.

With a truck like the ranger this is easily done.

I plan to use the lightest i.c.e. powertrain in 2wd. Manual...2.3 Mazda L.

Rear and front axles will have manual lockouts .....but auto hubs can be implemented.

The electric motor will drive the front through a bit different system...or just pop for a mach e type setup. ..

and the normal shit will drive the rear. There will be reduced utility but it will be easier to do then when I was thinking of converting the escort..Because of space and battery limitations at that time...which was going to be able to run on natural gas and gasoline. With the hubs unlocked in whatever mode your drag losses are nothing.... But you can drive anywhere.

If you are stuck....you can pair them for 4wd to get unstuck ect....


These current electric powertrains are good ..but I was really hoping for more hub motor development...

I want to rock crawl and trail ride with full control and zero rpm torque application....skid steering and turn table steering is going to be awesome.

 

[ericbphoto]

I want to rock crawl and trail ride with full control and zero rpm torque application....skid steering and turn table steering is going to be awesome.

That right there is what I could get excited about in a hybrid vehicle. That would turn me on more than my wife ever did.

 

[bobbywalter]

What is learned from this project will be nothing but win for idiots like us Eric.....


Looking forward to this build.

 

[PetroleumJunkie412]

Posting to get updates.

I still think EVs are a meme.

But, I'll watch for the DIY factor.

 

[bobbywalter]

Posting to get updates.

I still think EVs are a meme.

But, I'll watch for the DIY factor.

Yeah.....you need to go on a tour here at all of the r&d facilities.

It will frighten you. At least it does me. My dynotech neighbors are scrambling to get training in can bus and system layout cooling and comms.....because....just like the parts room....they soon will be OBSOLETE.

 

[bobbywalter]

Lead the way regular guy....

 

[Eddo Rogue]

Batteries are for power tools.

 

[pjtoledo]

batteries have powered forklifts for over half a century.