1996 Land Cruiser EV Conversion - EVJ80 Project

[PIP]

New adapter is nearing completion! @PIP, the reason it's not one piece is because the motor itself won't fit that far back into the trans tunnel so it needs to be towards the front end where the bellhousing fits. It should be smooooth and strong as.

I see now! Thanks for the explanation!

You are already deeply committed to this adapter I see, but if you ever do another one I'd suggest finding a machine shop with a HBM (Horizontal Boring Mill). We do this kind of work all the time and can make big parts with concentric flanges a long distance apart with precision. For a shop with a small lathe and mill this is a really big job, lots of hours. For a shop with big machines this is a quick, easy job.

Thanks for sharing the progress!

 

[J1000]

I see now! Thanks for the explanation!

You are already deeply committed to this adapter I see, but if you ever do another one I'd suggest finding a machine shop with a HBM (Horizontal Boring Mill). We do this kind of work all the time and can make big parts with concentric flanges a long distance apart with precision. For a shop with a small lathe and mill this is a really big job, lots of hours. For a shop with big machines this is a quick, easy job.

Thanks for sharing the progress!

Prosise Metal Works is doing the work and he has some impressive CNCs. The tube in the middle is actually off the shelf aluminum tubing from McMaster Carr I believe so only the ends needed to be milled and the bearing is pressed into an aluminum insert.

 

[PIP]

Prosise Metal Works is doing the work and he has some impressive CNCs. The tube in the middle is actually off the shelf aluminum tubing from McMaster Carr I believe so only the ends needed to be milled and the bearing is pressed into an aluminum insert.

Yeah, I get that. I saw his IG stuff. I'm just saying the simplest way to make this and make it lighter and with many, many less machining hours would be to laser cut a pair of flanges, weld them to a steel tube then face and machine both ends in one setup.

Mcmasters is a very expensive way to buy material. Aluminum is about $2/lb currently. I bet Mcmasters is double or triple that.

 

[John Young]

Eventually I want to try an electric conversion for either the RJ77 (22R carb engine) owned by my son, or my 75 petrol (1FZ carb) flatbed pickup. I'd love to piggyback off your work and PIP's suggestion.

 

[J1000]

I will be releasing a long form Christmas special on my YouTube channel from my trip to Moab this year. I have been neglecting the channel but I will be putting a lot more work into it from now on. I upgraded my PC and now editing 4k is a breeze compared to before. I had been trying to keep the videos chronological but I decided to just go straight to the good stuff and do the 4x4 driving first!

Be sure to subscribe to my channel www.youtube.com/UniqueMobility!

Teaser:

 

[Navyator]

@J1000

Curious as to your thoughts on gearing solutions. I know what you did here with the black box, but just wondering what other options you considered if any? For example, if you wanted to pull a Tesla drive unit and use that as a motor (without going straight to the wheels), it seems next to impossible given the axle ratios involved with the drive unit's incorporated gearbox. If you were in a situation with more disposable funds for a fun project, would you still go w/ the leaf setup?

 

[PIP]

@J1000

Curious as to your thoughts on gearing solutions. I know what you did here with the black box, but just wondering what other options you considered if any? For example, if you wanted to pull a Tesla drive unit and use that as a motor (without going straight to the wheels), it seems next to impossible given the axle ratios involved with the drive unit's incorporated gearbox. If you were in a situation with more disposable funds for a fun project, would you still go w/ the leaf setup?

This is exactly the way it's usually done. Tesla Large Drive Unit 4.5:1 Reduction Gear Set, EV West - Electric Vehicle Parts, Components, EVSE Charging Stations, Electric Car Conversion Kits - https://www.evwest.com/catalog/product_info.php?products_id=489 One would install the high range gearset in the Tesla gearbox. The axle ratio is good then.

I've been thinking about gearing options for this type of application for awhile. I have some ideas about improving what's available, but not sure it's needed in actual use. Basically making the gears for a two speed gearbox so you'd have the 4.5:1 high range and the 9:1 standard gears for a low range. I'm thinking the deep low range gearing would be problematic to control the power delivery though. If you stuffed your foot and motor acceleration/torque limit was the same I expect things would get real violent and break.

As a Tesla owner, I would like to a do a Tesla swap into something older while retaining the Tesla creature comforts. For the most part, I like the Tesla user interface. The drivability is superb.

 

[J1000]

@J1000

Curious as to your thoughts on gearing solutions. I know what you did here with the black box, but just wondering what other options you considered if any? For example, if you wanted to pull a Tesla drive unit and use that as a motor (without going straight to the wheels), it seems next to impossible given the axle ratios involved with the drive unit's incorporated gearbox. If you were in a situation with more disposable funds for a fun project, would you still go w/ the leaf setup?

As @PIP says you can get replacement gears for the Tesla drive unit to make the axle ratios all work and ~100MPH top speed. Super cool setup for a street driven vehicle but the underlying issue is that it's an AWD vehicle with no low range and no locking center diff at that point.

I'm a firm believer that low range reduction is truly needed for off-road EVs.

If money is no object I would probably get like a Electric GT power train or something like that but I would still adapt it to the stock transfer case.

Check out this video of the Hummer EV absolutely failing to climb a ledge my EV80 would climb in a second. Starts at the 8:00 minute mark:

 

[John Young]

To me that 'hummer ev' looks like a really ugly FJ Cruiser--and that is saying a lot, I think.

 

[Broski]

As @PIP says you can get replacement gears for the Tesla drive unit to make the axle ratios all work and ~100MPH top speed. Super cool setup for a street driven vehicle but the underlying issue is that it's an AWD vehicle with no low range and no locking center diff at that point.

I'm a firm believer that low range reduction is truly needed for off-road EVs.

If money is no object I would probably get like a Electric GT power train or something like that but I would still adapt it to the stock transfer case.

Check out this video of the Hummer EV absolutely failing to climb a ledge my EV80 would climb in a second. Starts at the 8:00 minute mark:

Can you say junk ? what a joke at more then 100k

 

[rdcnj]

What am amazing build.

Great job getting this going and documenting a lot of what you did.

Although small in terms of "capacity", you've done a huge task. Congratulations and please keep us updated on the progress as you keep dialing it in.

 

[J1000]

Merry Christmas! Check out my Moab Special!

 

[J1000]

Got the new drivetrain installed in the truck and it runs amazing now. Smooth as a Tesla. Set a new top speed record of 55 mph!! It definitely has more speed in it, can likely take it over 70mph. Working up to it.

One issue cropped up since I got it back together is that it won't charge. Not sure why I've been trying to troubleshoot it. Pretty pressing concern lol

 

[J1000]

Got the coolant and t-case oil systems plumbed and realized the reason I didn't use this PDM was because it had a broken coolant inlet. I was able to goop enough silicone on it to hold for now. Luckily there is not much heat or pressure in an EV cooling system vs. ICE.

I drove it a bunch today and did a 0-60 test. It was able to do 0-60 in 14.5 seconds! That's not too shabby and not far off from a stock brand new 1996 Land Cruiser. I bet a lot of 80 guys on here have trucks slower than that lol!

New top speed 64 mph

 

[ajordan1975]

Got the coolant and t-case oil systems plumbed and realized the reason I didn't use this PDM was because it had a broken coolant inlet. I was able to goop enough silicone on it to hold for now. Luckily there is not much heat or pressure in an EV cooling system vs. ICE.

I drove it a bunch today and did a 0-60 test. It was able to do 0-60 in 14.5 seconds! That's not too shabby and not far off from a stock brand new 1996 Land Cruiser. I bet a lot of 80 guys on here have trucks slower than that lol!

New top speed 64 mph

That’s awesome @J1000
Wana race??

 

[J1000]

That’s awesome @J1000
Wana race??

Hmmm yeah I'll race you with my V8 truck!

 

[ajordan1975]

Hmmm yeah I'll race you with my V8 truck!

no, 80 vs 80

 

[J1000]

no, 80 vs 80

Give me a head start

 

[J1000]

Prepping the truck for 2023 adventures! I'm going to be doing several events and car shows etc this year taking the EV80 all over the country.

This weekend I will be going to Lafayette Cars & Coffee tomorrow and Old Gang Ice Racing Fun Day on Georgetown Lake on Sunday. I'm doing the Rising Sun Snow Run the following week. And in March I am taking the EV80 to Matt's Offroad Adventures Wrecker Olympics in Hurricane, UT! Cruise Moab and possibly Lone Star Roundup as well. Should be just as busy all year!

Last week I got the truck inspected and registered as an EV in the state of Colorado! Now I am legally allowed to park at EV charging stations and exempt from emissions testing!

 

[John Young]

Congratulations! The regulatory side of this is really pretty key. Can I ask what have you got the range up to now? And are you thinking about whether it's practical to drive to these events or whether you still have to trailer?