Jeep CJ-7 full EV conversion

[4x4 EVC]

Hi All,

Here's my fully converted EV CJ-7:

The full build is over at the big site (ZERO disrespect intended!), JeepForum: Jeep CJ-7 EV Conversion


And in keeping with this sites dark theme, here' s my first night drive: 4x4 EVC .
The rest of my videos are here: 4x4 EVC

I'll post the specs in the next post.

 

[4x4 EVC]

Major Parts List

• Motor: NetGain Hyper9HV-IS - 144v - ~$6,000
• Battery: Tesla Model S modules x 7 (~22.8v per modules x 7 = ~160vDC (the AC part isn't rated, don't get lost...) - ~ $1,200 - $1,500 EACH module = a butt load of change....
• BMS (battery management system): Orion 2 BMS - 24S is my configuration (more on that later)
• Pack Charger - Elcon 6.6kw with fan cooling
• DC/DC Charger - Elcon
• HV JB - custom (HV JB = High Voltage Junction Box)
• LV JB - Hawkeye SCM - (Low Voltage Junction Box) - ~$1,200
• Adapter Plate - custom
• Coupler - custom
• Charging Station - Juice Box - or some other charging station - you can look up Juice Box EV and see what I'm talking about - I bought the 40amp one, plug-in version (vs hardwired to your house's eclectic panel) - mostly because they were sold out of the other ones

Range is about 120 miles.

Anybody can do this, I've decided to make this a business and do it as a Repower Starter Kit.

There's a ton going on about this project so PLEASE, ask any questions you want.

- Patrick

 

[4x4 EVC]

Here's a set of range testing if anybody cares:


I'm killing it on the range, averaging around 2.4mi/kWh ever since I figured out how to do Single Peddle Mode drivng. It does so much better off-road and and on surface streets then highway for range.

Hope you guys like it, it's easily the most fun I've EVER had in a Jeep and I've owned a CJ or Wrangler every single day of my life since I turned 15 years old, about 45 years ago!

- Patrick

 

[trampas]

Pretty cool, Patrick -

Anybody can do this, I've decided to make this a business

- Patrick

If you do make it a business and decide to offer merchandise here, you would need to purchase a vendor's yellow skull. Same as the old place, no disrespect.

 

[NorCalJalopy]

Weight after the conversion?

 

[4x4 EVC]

Pretty cool, Patrick -



If you do make it a business and decide to offer merchandise here, you would need to purchase a vendor's yellow skull. Same as the old place, no disrespect.

NONE taken and I would expect nothing less!

And THANKS, it's suck a blast!

 

[4x4 EVC]

Weight after the conversion?

On paper, 270lbs less the 2900 stock for that year (or close to that).

I need to take it to a scale.

 

[NorCalJalopy]

On paper, 270lbs less the 2900 stock for that year (or close to that).

I need to take it to a scale.

Less?! Impressive. It’d be a cool option for the weekend warrior or a fun in the town commuter. I need that to run to the lake to go fishing on the weekends.

 

[4x4 EVC]

Less?! Impressive. It’d be a cool option for the weekend warrior or a fun in the town commuter. I need that to run to the lake to go fishing on the weekends.

Thanks!

Between the CJ, YJ and TJ, my target grouping to start with, there's about 3 million of them. I think to start, my goal is to have a solid, affordable repower option that surpasses stock in all areas except longer, surface rangers and kills it in off-road range.

That and something that hasn't been fully explored yet, or at least not said outload - Jeep reliability. EVERYDAY driver, low to no maintenance.

I'm not intending to building a rock crawler, I'm trying to build a repower solution that others might extend as they see fit.

 

[Swayzeexpress]

Thanks!

Between the CJ, YJ and TJ, my target grouping to start with, there's about 3 million of them. I think to start, my goal is to have a solid, affordable repower option that surpasses stock in all areas except longer, surface rangers and kills it in off-road range.

That and something that hasn't been fully explored yet, or at least not said outload - Jeep reliability. EVERYDAY driver, low to no maintenance.

I'm not intending to building a rock crawler, I'm trying to build a repower solution that others might extend as they see fit.

What would the all cost in be if you got these going?

 

[4x4 EVC]

What would the all cost in be if you got these going?

THIS IS NOT AN AD - gotta' say stuff like that to keep me out of trouble from everyone...

GREAT question, I welcome ANY comments about this. Also, unlike $300,000 completely restored and tricked out Ford Broncos (?!?), Defenders, etc., etc., we don't want to do ANY restromod work at all. You bring it in dirty, I give it back dirty but Repowered.

My thought is a Starter Repower Kit - $29k - NOT including batteries or de-ICE'ing, inverter cooling only.
Level 2: same as Starter Kit but with full liquid cooling of the packs and power steering - $34k.
All in, batteries, cooling, de-ICE'ing, power steering, $50,000.

One of the big things is delivery time - since we aren't interested in restoring your rig and we're only focusing on those models and years, we think we can turn around a Repower install in under a month. By comparison, the average time for an EV conversion is around 18 to 24 month and cost around $100k!

Like I said, I'm open to any thoughts you guys might have to this proposed pricing.

- Patrick

Couple notes:

• Batteries - If you want to do some research, I'm using 7 Tesla Model S battery modules, the price continues to drop slowly but around $1k per module if you look hard. Remember, they have to all be from the same vehicle with low miles.
• De-ICE'ing - I'm figuring one day labor and let the customer take ALL the removed parts or sell everything to a Jeep parts guy with the net proceeds going back to the Customer / cost of the Repower Kit install.

 

[Swayzeexpress]

Reads like an ad

Good luck man!

 

[4x4 EVC]

Reads like an ad

Good luck man!

Does the pricing sound about right - regardless of what it costs, and it's not cheap, does it sound reasonable?

 

[NorCalJalopy]

Does the pricing sound about right - regardless of what it costs, and it's not cheap, does it sound reasonable?

Price could be right. Reasonable? Depends on the person. I’m sure with time the price could come down with parts just like anything else. 30k puts lots of people out of that price range. For that or even less I could get a buggy and live out my rock crawling and camping dreams. Have you thought about Nissan leaf, and Chevy, ford parts?

 

[SLOWPOKE693]

You get the "all in" package pricing down to $15k and you MIGHT have a sustainable business model. At $30-$50k you will maybe attract a handful of customers if that.

You are selling a novelty for a premium. I can buy an EFI kit and a shitload of gas for the same vehicle for a lot less than $30k and not be stuck with a range problem and long "refueling" times.

 

[Skinny]

I really like what you have done here but I think your business model is a bit skewed. Jeeps aren't worth that when they are brand new. Sure it's a niche and I'm sure you could sell some.

I just don't see how anyone is going to justify spending that kind of coin on a Jeep just to make it electric. I don't think many people want to drop that kind of coin on a power train in a truck that is worth a third of the value of just that.

That's a tough sell. I like your truck. I think EV swap kits will be a thing in the future. Maybe if pricing comes down and financing is available that will happen faster.

 

[blakes]

I think EV swap kits will be a thing in the future. Maybe if pricing comes down and financing is available that will happen faster.

Yep

When these things get down to a reasonable price, I'd be game.

78 j10 on tons, 42's, nv4500, atlas 4spd

I live offgrid on solar across the street from FS trails. I'd love to bolt an EV motor to the nv4500 and take a quick run up the mountain and spend the next few days charging it on a level 1 charger.

 

[4x4 EVC]

Price could be right. Reasonable? Depends on the person. I’m sure with time the price could come down with parts just like anything else. 30k puts lots of people out of that price range. For that or even less I could get a buggy and live out my rock crawling and camping dreams. Have you thought about Nissan leaf, and Chevy, ford parts?

Completly agree, depends on what a customer wants.

I've got a short waiting list of 14, the average price is ~$41,000, each has different reasons, some are as simple as: 'I've had this Jeep my whole life and want to pass it down to my daughter, she want's my Jeep but not the headache of the blah, blah...'.

Or, I get this one as a variation of that one, 'My son and I want a big project for the Jeep and this fits with what he see coming up next in the world.'.

Or, I have a Tesla (just that car) and it's just like every other Tesla out there, I want a Jeep like I had but all electric because I love what my Tesla does (electric, not speed what what he meant).

As for used parts, other then the Tesla Battery Modules, everything else is cheaper then used and it all works together. My battery boxes are kinda' complicated, each one cost about $1500 and up, ten-million stupid little assembly steps in each one, it's a pain.

I'm shooting for .05% of the 2 million CJ, YJ and TJs that are out there that want their favorite vehicle to be all electric.

Hell, if I could make it cheaper, I would, in a heart beat.

Have you seen the Defender EV conversions (spoiler alert, those are some rich ass folks!!)?

 

[4x4 EVC]

You get the "all in" package pricing down to $15k and you MIGHT have a sustainable business model. At $30-$50k you will maybe attract a handful of customers if that.

You are selling a novelty for a premium. I can buy an EFI kit and a shitload of gas for the same vehicle for a lot less than $30k and not be stuck with a range problem and long "refueling" times.

See above reply to cover some of what I completely agree with.

I don't see how I can come down in price till I get above LVP (Low Volume Production), it's those damn batteries, they are soooo very expensive. About $1500 each! Good news, they are coming down but, expensive AND the cheapest on the market, by a LOT. As it is now, I squeeze my vendors by only putting in orders for 4 or more whatever's at a time AND paying in cash.

As for the EFI kit + gas for life - I suspect, someone looking to drop that much cash on a used repowered Jeep isn't thinking about gas at all.

Lastly, range off road for an EV is monstrously superior to any ICE Jeep for two reasons: 1. No ideal, 2. Regen - every up on the trail, has a regen down on the way back.

THANKS for your reply!!

 

[4x4 EVC]

I really like what you have done here but I think your business model is a bit skewed. Jeeps aren't worth that when they are brand new. Sure it's a niche and I'm sure you could sell some.

I just don't see how anyone is going to justify spending that kind of coin on a Jeep just to make it electric. I don't think many people want to drop that kind of coin on a power train in a truck that is worth a third of the value of just that.

That's a tough sell. I like your truck. I think EV swap kits will be a thing in the future. Maybe if pricing comes down and financing is available that will happen faster.

I've thought about many of those things also Skinny - as for who, just look at the fools paying $300,000 for a full restomod 1971 Ford Bronco - not a single company, there are at least three of them out there, churning out crappy ass restored Fords that I wouldn't have taken for free in 1971!

Don't even get me started on the EV Defenders - there's handful of those guys, cheapest one I've seen was $80,000!

AND, thanks for the compliment, appreciate that!

I agree completely, it will come, might take a bit but, if I build it now, I'll have it ready for the masses tomorrow.

 

[4x4 EVC]

Yep

When these things get down to a reasonable price, I'd be game.

78 j10 on tons, 42's, nv4500, atlas 4spd

I live offgrid on solar across the street from FS trails. I'd love to bolt an EV motor to the nv4500 and take a quick run up the mountain and spend the next few days charging it on a level 1 charger.

It's the price, yep, I hear you all, loud and clear.

Agree but, of the 2 million of them out there, I think I can find .05% of them that want it. I've got 14 on the list. If 2/3s of them flake, that's still about 5 of them that are already saying yes.

And trust me, they breed - every time I've been next to any two Jeep owners and they are staring at my proof of concept running EV Jeep, they want it, but probably not at that price...

As for running up the mountain, you recharge on the way down - regen loves it's friend Mr. Gravity.

THANKS for the reply!

 

[4x4 EVC]

Yep

When these things get down to a reasonable price, I'd be game.

78 j10 on tons, 42's, nv4500, atlas 4spd

I live offgrid on solar across the street from FS trails. I'd love to bolt an EV motor to the nv4500 and take a quick run up the mountain and spend the next few days charging it on a level 1 charger.

...sorry, I just figured out your short hand - 1978 J10 - send me pictures please - is that the one with the rounded CJ like fenders? I LOVE that Jeep truck!!! Not that I need a distraction but that would be a GREAT donner for an EV, so much room for battery modules.

 

[blakes]

Probably not what you were thinking

 

[4x4 EVC]

Probably not what you were thinking

A tad skeletal...

By chance, was it a Honcho in a previous incarnation, or was that a later package?

That looks like the funest rig, almost Tonka toy like - what a beast!

 

[NorCalJalopy]

Completly agree, depends on what a customer wants.

I've got a short waiting list of 14, the average price is ~$41,000, each has different reasons, some are as simple as: 'I've had this Jeep my whole life and want to pass it down to my daughter, she want's my Jeep but not the headache of the blah, blah...'.

Or, I get this one as a variation of that one, 'My son and I want a big project for the Jeep and this fits with what he see coming up next in the world.'.

Or, I have a Tesla (just that car) and it's just like every other Tesla out there, I want a Jeep like I had but all electric because I love what my Tesla does (electric, not speed what what he meant).

As for used parts, other then the Tesla Battery Modules, everything else is cheaper then used and it all works together. My battery boxes are kinda' complicated, each one cost about $1500 and up, ten-million stupid little assembly steps in each one, it's a pain.

I'm shooting for .05% of the 2 million CJ, YJ and TJs that are out there that want their favorite vehicle to be all electric.

Hell, if I could make it cheaper, I would, in a heart beat.

Have you seen the Defender EV conversions (spoiler alert, those are some rich ass folks!!)?

I totally get it. If you need an employee let me know lol.

Anyone making waves in a market with something against the grain is a ok in my book.

Have you thought about building a Jeep for king of hammers? There’s one guy kinda local to me that has an s10 that he been working out the kinks with. I believe it’s call the “test 10” he’s been on the wheeling wine and whiskey podcast.

 

[4x4 EVC]

I totally get it. If you need an employee let me know lol.

Anyone making waves in a market with something against the grain is a ok in my book.

Have you thought about building a Jeep for king of hammers? There’s one guy kinda local to me that has an s10 that he been working out the kinks with. I believe it’s call the “test 10” he’s been on the wheeling wine and whiskey podcast.

No, haven't heard of him, I'll see if I can find him with your clues...

I'm hoping to do a steady 3-5 per month, trust me, if I get there, the Now Hiring sign will be fully unfurled!

 

[4x4 EVC]

Found the King of Hammers EV build: Meet the couple that built an EV rock crawler for King of the Hammers

First of all, King of Hammers is the scarcest thing I've ever seen in my life - how many people die each year, just the spotters look like an endangered species out there - wow, crazy!

 

[NorCalJalopy]

Found the King of Hammers EV build: Meet the couple that built an EV rock crawler for King of the Hammers

First of all, King of Hammers is the scarcest thing I've ever seen in my life - how many people die each year, just the spotters look like an endangered species out there - wow, crazy!

It’s a good time at KOH, I’m morning into the night time shenanigans. I just stay in camp and enjoy a nice drink and look at all the crawlers and drool.

 

[Treefrog]

I plan to read the build thread when I get a chance, but I do have a few questions.

What transmission did you use?
Does it have power steering, and if so how is that done?
What axle ratio?
What is the run time going slow off road?
How water proof is it?

I wish someone would come out with a better option than the hyper9 for doing repowers.

 

[4x4 EVC]

I plan to read the build thread when I get a chance, but I do have a few questions.

What transmission did you use?
Does it have power steering, and if so how is that done?
What axle ratio?
What is the run time going slow off road?
How water proof is it?

I wish someone would come out with a better option than the hyper9 for doing repowers.

No worries at all, I love these kinds of questions!

My kit bolts directly to the stock transmission. On the CJ-7, that would be a T176. I use a custom direct coupler inside a bullet proof Torque Adapter Cover:

(slightly older picture with prototype plywood Girdle still on, that's now steel.)

Power Steering - Hell's yes it does. I used the Volvo unit that has the pump built into it. So, I don't need to run any other hoses other then the Hi and Lo between the pump and the Saginaw (stock) knuckle. It has outperformed all expectations so far. NOTE: no super use off-road yet.

If you look at the very first picture in this thread, you can see it just to the right of the Master Cylinder. I had a custom high pressure hose made by a race company here in SoCal.

In this build, I've got a Dana 60 in the back (long story, not a smart one, from years ago), 3.73:1 with a D.Locker.

Off-road range is so fluid but significantly higher then ICE set ups. Right now, my ranges are around 2.5mi/kWh - that really doesn't translate to time off-road. My first off-road venture that was close to a ;stock Jeep necessary' trail resulted in almost no use of battery and lasted around 1.5 hours with a total distance of about 7 miles. It's the ideal, or I should say, the lack of ideal that is at work here. Not needing to bleed gas while waiting behind someone or something is huge.

Would that continue into harder trails - I doubt it. While the miracle of instant and 100% torque is a game changer all by itself, it does eat into the Pack voltage. I'm sure that isn't a surprise, it eats into gas tanks also.

Short answer, all weekend, you should be fine with plenty of juice.

Waterproof: The rear Battery Box is built and rated at IP66 - water proof. That box is aluminum, welded on 5 sides with a lid that has 28 bolts keeping it sealed. That was our intent for that vulnerable position.

The other Battery Boxes are water resistant and sit above the axel by about 7", we went for IP5. By the way, the motor is rated at IP66 also.

NetGain Hyper9HV motor - what don't you like about it, it's made by Dana, it's small, 98% efficient (compared to a finely tuned ICE set up that can't exceed 29% efficiency EVER), doesn't cost much, around $5,600, very reliable, 10,000 max RPM, air cooled (cheaper, not necessarily better...), it works great.

BUT, I get what you're saying - once you go one step up to any other motor that's available now (Cascadia motors), you need to move up to a 400 volt system and things get very expensive from there on. Looking at Dana's TM4 deep line of motors and such (Dana makes the Hyper9HV motor), I would bet my bottom dollar they'll have a larger array of options that will work in the near future. I mean it's Dana, they helped birth Jeep.

Thanks for the cool questions!

- Patrick