Just posted my New Member introduction here: Greetings from Germany
I’m considering to convert my 1997 Jeep Cherokee XJ (currently fitted with a 4.0 L Inline 6) to reduce noise, emissions and potential failure points in the system. Besides that, I’m just a passionate tech guy and love a good project. Depending on how feasible the conversion is and how it turns out, I’m then also considering to put together a conversion kit for the XJ as well as possibly starting a business to convert 4x4s to electric, but those are just some thoughts for the next years.
Your skill level with auto mechanics and fabrication
I'm a car mechanic, also working on all kind of projects continuously. I know how to use a welder… the tire carrier on the Jeep is DIY
The range you are hoping to get (how many miles/charge)
Looking at roughly 100 km (60 miles) to keep cost and weight down for the beginning, might want to increase that further down the line
What level of performance you are hoping to get
Don’t need to go fast (80km/h, 50mph), but I need torque for offroading and climbing mountain roads. Also, I still want to be able to tow small trailers (750 kg, 1650 lbs)
How much money you are willing to put into your project
As much as required, as little as possible.
What parts you've already considered, if any.
At the moment, I want to go for a 96V system… just to keep it safe
For the batteries, I would prefer to use OEM modules because of cost and their good packaging... for example the VW ID3 modules. While we’re at it, how would I connect, let’s say an Orion 2 BMS, to these modules (since the cells are packaged already)? Would I still need to get a cell package with the BMS itself?
For the motor, I’m really torn between DC (brushed) / AC (induction)..
DC because I can get used motors.. aiming for the ZAPI H2 controller, which also offers regen (which should be possible with non-advanced brushes on a stock 80 V motor)
AC because it’s more sophisticated, but since I want to run 96V, I would need to buy a new motor (all OEMs are high-voltage)
Besides deciding between DC/AC, I also need to figure out how to implement proper cooling while also protecting the motor from water and mud. Watercooling on ACs seems to be the easiest.. For the DC motor, I would build an encasement (inside aerodynamically optimized) with an integrated cooling fan
In terms of weight, I’ll actually end up lightening the Jeep. At the moment, it’s roughly 1,7t (3750 lbs)… with removing the engine (250 kg) and all the other stuff, I should end up at around 1,5t (3300 lbs) after the conversion.
I’m posting here to get help deciding between DC/AC mostly, as well as just hearing your opinion on the whole conversion, if it makes sense in your eyes, what you would make different or if you have other ideas/input.
Looking forward to your replies!
P.S. Some pictures of the Jeep