Wiktor Wise
Converting a Jeep to electric is a complex process that requires careful planning and execution. It involves removing the old engine and components, selecting a suitable electric motor, calculating gear reduction ratios, designing adaptors, and installing battery modules. The process can vary depending on the Jeep model and desired specifications. Some popular choices for conversion include the Jeep Wrangler and older Jeep models like the 1942 Ford Jeep. Safety considerations are crucial when working with high-voltage systems, and individuals should be aware of the potential dangers and costs involved. Online resources, such as forums and YouTube channels, provide valuable insights and step-by-step guides for those interested in pursuing an electric Jeep conversion.
| Characteristics | Values |
|---|---|
| First Step | Remove the old Jeep engine and its components |
| Engine Weight | 450 pounds |
| Other Removed Components | Gas tank, flywheel, clutch, radiator, transmission |
| Total Removed Weight | 650 pounds |
| Next Steps | Pick a motor, tire size, gear reduction ratio, adaptors, battery modules, battery size, and accessories |
| Motor Options | Nissan Leaf, Volvo, Tesla |
| Battery Voltage | 72V |
| Battery Type | Lead acid |
| Number of Batteries | 6 |
| Battery Voltage Doubling | Possible by disassembling battery modules and reconfiguring into new modules with different electrical connections |
| Drivetrain | Use an adapter plate to mount the motor to the existing transmission |
| Powered Axles | Under development by Magna and Allison, could simplify conversion for solid axle vehicles like Wranglers |
| Tesla Parts | Motors and batteries commonly used in conversions, sourced from salvaged vehicles |
| Range | 120 miles with a 90kWh battery in a TJ Wrangler, impacted by aerodynamics and rolling resistance |
| Dashboard | Aftermarket options available with features like speedometers, tachometers, GPS, radio, storage, and phone connectivity |
| Cooling System | Liquid cooling with copper pipes for active cooling |
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What You'll Learn
Remove the engine and other components
Removing the engine and other components is the first step in converting a Jeep to electric power. This process involves taking out the large petroleum-powered engine, which typically weighs around 450 pounds, along with several other associated parts. These include the gas tank, flywheel, clutch, radiator, and transmission, bringing the total weight of removed components to approximately 650 pounds.
When removing the engine, it's important to note that certain functions, such as power steering and power brakes, may no longer work as they did with the original setup. To address this, you can get creative and source replacement parts from other vehicles. For instance, you could use electric power steering from a Volvo, a brake booster from a Tesla, and an "electron" pedal from a Nissan Leaf.
The removal process can be made simpler by opting for an adapter plate to mount the electric motor to the input for the transmission. This approach reduces the amount of engineering work required, although it may result in slightly lower efficiency. Alternatively, for vehicles like the Wrangler with solid axles, powered axles are an option that can simplify the conversion process even further, requiring just an axle swap.
Before beginning the removal process, it is crucial to plan and research thoroughly. This includes understanding the weight and dimensions of the components you will be removing, as well as deciding on the type of motor, tire size, and overall gear reduction ratio required for your desired vehicle speed.
It is worth noting that converting a Jeep to electric power is a complex and potentially dangerous task due to the high voltage and amperage involved. Therefore, it is essential to prioritize safety and seek out relevant resources, such as books, online forums, and kits, to ensure a successful and secure conversion.
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Choose a motor and tire size
Choosing a motor and tire size is a crucial step in converting a Jeep to electric power. Here are some detailed guidelines and considerations for making those choices:
Choosing the Motor:
Firstly, it's important to research and select a motor that is compatible with your Jeep's specifications and your desired performance outcomes. Consider the power, torque, and efficiency of the motor to ensure it can handle the weight and performance demands of your Jeep.
You can choose between an AC or DC motor. Many Tesla motors are AC induction motors, which are efficient but may have lower efficiency than permanent magnet motors. DC motors, on the other hand, require a motor controller.
Consider the weight of the motor and its impact on the overall weight distribution of the Jeep. A heavy motor may affect handling and stability, especially if it raises the center of gravity too high.
Additionally, pay attention to the motor size. Ensure it fits within the available space in your Jeep, and be mindful that a motor that is too small may overheat and fail, as seen in some DIY conversion stories.
Choosing the Tire Size:
When it comes to tire size, there are a few factors to consider. Firstly, larger tires can impact aerodynamics and power consumption. Bigger tires can increase drag, leading to higher power consumption, especially at highway speeds. This may result in reduced range for your electric Jeep.
Calculate the overall gear reduction ratio required for your tires based on the maximum motor RPM and your desired maximum vehicle speed. This will help you choose the right tire size that aligns with your performance goals.
Consider the type of terrain you plan to drive on. If you intend to use your Jeep off-road or on challenging trails, you might opt for larger tires that can provide better ground clearance and traction. Ensure that your motor can handle the increased load and rotational mass of larger tires.
Finally, think about the overall aesthetic and functionality you want for your Jeep. Tire size can significantly impact the look of your vehicle, and you may want to maintain a certain style or keep the tire size consistent with the original Jeep design.
In summary, choosing the right motor and tire size for your electric Jeep conversion requires careful consideration of performance, efficiency, weight distribution, and your intended use. Research and calculations will help ensure that your choices align with your desired outcome for a successful electric Jeep conversion.
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Calculate gear reduction ratio
The gear ratio is a critical factor in determining the output speed and torque of an electric motor. It is the ratio between the input and output speeds and is influenced by the type and number of gears in the gearbox. The gear ratio can be calculated in several ways, including as a fraction, a decimal number, or an ordered pair of numbers separated by a colon. For example, a gear ratio of 40:10 or 40/10 can be simplified to 4:1 or 4, indicating that the input gear must rotate four full turns for the output gear to complete one full rotation. This setup results in a gear reduction in speed but provides greater torque.
To calculate the gear reduction ratio for a spur gear motor, you need to consider the number of gears connected. For instance, if a spur gear motor has five gears connected, the reduction ratio can be calculated accordingly. This calculation will give you the relationship between the input and output speeds of the motor.
The type of gearbox used also impacts the reduction ratio. A spur gearbox, the most common and cost-effective type, typically has a 1:1 ratio. On the other hand, a planetary gearbox, resulting from the coupling of a pinion and a satellite that works on an outer ring gear, generates more torque in the same space compared to a conventional spur gearbox. The reduction ratio for a planetary gearbox is calculated based on the correlation between the number of teeth on the pinion (sun gear) and the outer ring gear.
Online tools and calculators can also assist in determining gear ratios and final drive ratios. These calculators often require input such as engine RPM, transmission gear ratio, tire height, and vehicle speed to provide an estimate of the gear ratio and resulting performance. It is important to note that these calculators are for estimation purposes, and actual results may vary.
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Build adaptors and gear reduction box
Electric motors are generally more efficient and produce peak torque from a stop, and over a broader rpm range. This means that most electric car conversions could benefit from a smaller, lighter transmission package. For example, a single forward speed reduction gearbox, like the one used in all Tesla vehicles and most new plug-in electric cars.
When building adaptors and gear reduction boxes for an electric Jeep conversion, there are a few considerations to keep in mind. Firstly, the overall gear reduction ratio required for the tires should be calculated based on the maximum motor RPM and the desired maximum vehicle speed. This will help determine the type and size of the gear reduction box needed.
The gear reduction box will be used between the motor and the transmission or transfer case. It is important to ensure that the gear reduction box can handle the electric motor's torque continuously and that it is properly sealed. Additionally, a parking pawl or similar mechanism is necessary to lock the brakes when parking.
The adaptors used in the conversion process should be designed or sourced based on the specific motor and transmission or transfer case being used. Adapter plates are commonly used to join the electric motor and the reduction gearbox. It is also worth noting that conventional transmissions, whether manual or automatic, are designed for internal combustion engines and may not be suitable for electric car conversions due to their weight and size.
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Install battery modules
Installing battery modules is a crucial step in converting a Jeep to electric power. This process requires careful planning and consideration to ensure the battery modules are set up optimally for your vehicle. Here is a detailed guide on how to install battery modules in a Jeep conversion:
Determine Battery Requirements
Before installing the battery modules, it's essential to understand the specific requirements of your electric Jeep conversion. Calculate the overall gear reduction ratio required for your tires, taking into account the maximum motor RPM and desired maximum vehicle speed. This calculation will impact the type and size of battery modules you need.
Choose Battery Type
There are different types of batteries available for electric vehicle conversions, such as lead-acid batteries or more modern lithium-ion (LiON) batteries. Consider factors such as voltage, capacity, weight, and safety when choosing the right type of battery modules for your Jeep.
Find Installation Locations
Identify one or multiple places within the Jeep to install the battery modules. Consider the size, shape, and weight of the battery modules when deciding on their placement. Ensure that the installation locations provide easy access for maintenance and do not interfere with other critical components.
Build and Configure Battery Modules
If you're building your own battery modules, disassemble battery modules from scrapped electric vehicle batteries into individual cell slices. Reconfigure these slices into new modules with the desired voltage and capacity. Ensure that the battery modules are connected in series or parallel to match your voltage requirements.
Connect the Batteries
Connect the battery modules to the vehicle's electrical system. This includes linking the batteries to the motor, inverter, battery management system, and other components. Ensure that the connections are secure and follow the manufacturer's instructions or guidance from online resources for your specific battery type.
Implement Cooling and Safety Measures
Battery modules, especially in electric vehicles, can generate significant heat. Implement a cooling system, such as liquid cooling or active liquid cooling with copper pipes, to maintain optimal temperature and performance. Additionally, follow safety protocols, such as using thick enough wires and lugs to prevent melting due to high voltage and amperage.
Converting a Jeep to electric power is a complex process that requires careful planning and execution. It is essential to refer to detailed guides and resources specific to your Jeep model and chosen battery type for a successful conversion.
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Frequently asked questions
The first step is to remove the engine from the Jeep. This will involve removing several other components, such as the gas tank, flywheel, clutch, radiator, and transmission.
You will need to consider the type of drivetrain you want to use. Modern EVs use motors at the wheels, but adapting a Jeep often involves mounting an electric motor to the existing transmission using an adapter plate. This is a less efficient but simpler approach. You may also want to consider using a powered axle, which is currently being developed by companies like Magna and Allison.
The type of battery you use will depend on factors such as the voltage of your system and the range you want to achieve. Lead-acid batteries are commonly used in 72-volt systems, while more advanced options like lithium-ion batteries can provide longer ranges. You may also consider using salvaged Tesla batteries, which are commonly used in conversions and can offer a safe range of around 120 miles in a TJ Wrangler.
