Soooo I got bored and decided to run some of these specs through my performance simulator. I tend to get a bit... well... skeptical when technical question are met with instagram posts.
So what this has going for it is that it retains the transmission. However, performance in many areas will fall well short of the 2F powertain due the very low continuous performance of air cooled motors. Also, induction motors have worse efficiency at lower RPMs than do permanent magnet motors meaning you want to keep the RPM's up to maximize efficiency. Here, however, there is a potential problem. Note the torque line and where it starts to taper off. That is a region we call flux or field weakening and is also the region of peak operating efficiency. To reach that you have to rev the transmission input shaft 6000 RPM and beyond. That is higher than that gearbox was likely designed to rev. If it starts throwing oil off of the gear teeth rapid wear will result. I am not saying you cannot rev it that high, just that there is a real risk of rapid gear and/or bearing wear. Assuming you try to keep the transmission under say 5k means you never reach the motor's region of peak efficiency - or peak power. Note that I did not account for the added windage losses from revving that high.
View attachment 2116805
I used the following constants in my simulation
| Crr | 0.006 |
| Cd | 0.50 |
| A | 3.3 |
| Mi | 1.04 |
| lb | 4500 |
| kg (mass) | 2041.2 |
| N | 20017 |
| mgCrr0 | 120 |
| Crr1 | Ignored |
| mg = | 20017 |
| ρ= | 1.2 |
I used the 3 speed trans ratios of 2.75, 1.69, and 1:1.
Rear axle 4.11
I assumed 33" tires though the .006 Crr is likely worse in real life but I gave it the benefit of doubt.
Note the graph below.... The peak power numbers look great but air cooled motors heat quickly, as in seconds, and have low continuous power compared to liquid cooled motors. Thus any continuous load operation like high way cruise and grade climbing needs to be assessed at continuous power, not peak. Based on that, the FJ40 will have a high way cruise speed of only 70 MPH as you will heat the motor just getting onto the freeway. While startability at peak is great, continuous is only 12% which is awful for an on road passenger vehicle. Consider pulling over on a 6% grade, attempting to get back on the road climbing the road crown, and having the asphalt raised creating a ridge off of the shoulder can create an instantaneous grade of 20%. You'd have to wait until the motors cooled to climb over that ridge.
View attachment 2116809
Now looking at consumption, I could not find an efficiency map for these motors so I fudged one from other induction motors. There are a number of drive cycles one can use, I used the CARB HDDT 65. It is typically a heavy duty cycle but it does mimic SoCal driving rather well and the 40 should easily meet the trace which the simulator suggests it does. Here I get .55 kWh/mi. To put that into a range number, if you have 47kWh and say allow 90% of that to be used, you then have 42.3 kWh of usable energy. Divide that by .55 and you have 77 miles of range. That's not very much and definitely not enough to go wheeling/camping etc... with a rig like that.
Finally, the numbers we all love, 0-60 times. Peak power I am getting around 15 seconds accounting for time to shift gears which could be improved if you are willing to torture the gearbox and rev >6k RPM. However, at continuous power you will be pushing 40 seconds, and in 4-0 seconds to get to 60 MPH. Realize that you will warm the motors just getting to the freeway. If you are climbing an uphill on ramp, you will probably miss that 2F...
My recommendation to the OP would be to consider a lower revving higher torque PMAC machine instead of the induction machine. Also, consider going up in voltage if you can. That will help performance and efficiency because let's be honest, the AC50 and that line of motors is really forklift/golf cart grade hardware. Think about sizing the motor for continuous power, which will require more motor but will then deliver much better and more consistent performance - and yes it will cost more but I have to believe the 2F has to set the performance floor. Consider that all, and I mean every single EV on the market uses liquid cooled motors and higher DC voltage for these reasons.
Please let me know if I can be of further help.
Frank
