Toyota Hiace poptop conversion

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teresah
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Toyota Hiace poptop conversion

Post by teresah » Wed, 12 Sep 2018, 12:17

Hi,

Our trusted (petrol) family Toyota HIAce motorhome has wheezed itself to a meeting with the undertaker.
It is well past an engine reco and have been scratching my head about whether to just throw it away
(a pity as it is well setup) or to try and find some way to keep it alive. An EV conversion may be the way to go.
I have followed the DIY'ers for 20 or so years now always admired them and hoped to one day do one myself.
Unfortunately I haven't been taking too much notice recently (mesmerised by Tesla) so have lost touch with the gear available now.
Also now getting a bit long in the tooth! :roll:

Anyone got any ideas/suggestions for me?

Desired performance is modest (it is a leisure vehicle only) and range not too critical. Jusdt need to get to a camping area and plugin!
What sort of motor (AC/DC), voltage, and controller does one go for these days?
I haven't found anyone interested in doing a conversion (in Vic) either, but hey, they must be out there.

Thanks for taking an interest.

Greg

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jonescg
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Re: Toyota Hiace poptop conversion

Post by jonescg » Wed, 12 Sep 2018, 12:56

How much space in the floor of the camper is there? Seems a good spot to place batteries but I'm not sure how much room you have to play with.
AC motors of respectable performance are still more expensive than DC motors, and battery cells are better nowadays, not cheaper.
Some photos would be ideal if you can share them.
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Richo
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Re: Toyota Hiace poptop conversion

Post by Richo » Wed, 12 Sep 2018, 13:01

I'm guessing like this
Image
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Richo
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Re: Toyota Hiace poptop conversion

Post by Richo » Wed, 12 Sep 2018, 13:07

Hmm I'd say Warp/Impulse9 with Zeva controller and 12 of the 12V60Ah LiFePO4 packs.
That's $11k for the main parts...
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teresah
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Re: Toyota Hiace poptop conversion

Post by teresah » Wed, 12 Sep 2018, 14:37

Yep,

My camper looks exactly like this photo - albeit with a few more kays on it.
My guess is there would be plenty of room under the seats in the rear for batteries
but that may be problematic for any venting during charging - not sure what the rego nazis
would say about this. Also not great for the centre of gravity? It doesn't handle to well as it is!

$11,000 for parts seems OK but then there is still the labour to do the conversion.
How much would that likely cost - and who could/would do it? Any ideas?

Greg

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jonescg
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Re: Toyota Hiace poptop conversion

Post by jonescg » Wed, 12 Sep 2018, 18:00

Labour is a very flexible part of the conversion. It's more about how long you are happy to have the vehicle out of action, and whether the shop doing the conversion has the room for it during that time. Otherwise if everything comes together I would budget a solid 40 hours of car-time. Other assemblies and components will need to be put together before entering the vehicle, and these may be done outside of the workshop to save time and money. The battery will end up costing between $10k and $20k depending on how far you want to go, or how little room you are willing to dedicate to batteries. As I said earlier - DIY lithium batteries have certainly gotten better, but they didn't get cheaper. So it's probably still about $450/kWh but that battery will weigh less and take up less space.
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Richo
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Re: Toyota Hiace poptop conversion

Post by Richo » Thu, 13 Sep 2018, 12:42

12 x 12V60Ah -> 144V60Ah -> 8.6kWh $5,760 ~40km range
I live in the city and most camping area's are way further than 40km.

Given the car is loaded up already I'd be surprised if you could even put enough batteries in it to go anywhere useful before you get to the GVM.

Any ideas how far you were hoping to go since you could be anywhere in the world?
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teresah
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Re: Toyota Hiace poptop conversion

Post by teresah » Fri, 14 Sep 2018, 11:27

Something is wrong with these calcs surely? Not sure of my battery nous but surely 12 bats give more range than this?
I need something like 100 - 120 kms to make a reasonable area to be able to reach.

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Re: Toyota Hiace poptop conversion

Post by brendon_m » Fri, 14 Sep 2018, 12:24

The rule of thumb I heard for a 144v lithium system is range is 75% of amphours.
Ie 144v 100ah will give 75km.
So 40km from 60ah is probably a good estimate. That being said a hiace has the aerodynamics of a brick so it'll be worse no doubt, especially at speed.

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Richo
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Re: Toyota Hiace poptop conversion

Post by Richo » Fri, 14 Sep 2018, 12:33

If you just go all out for 150km range you'd need more like 27kWh.
So about $18,000 just for the batteries.
AND wait for it... 431kg.

So there is no way your pop top can handle another 431kg.

So LiFePO4 are out of the question.
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Richo
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Re: Toyota Hiace poptop conversion

Post by Richo » Fri, 14 Sep 2018, 12:40

NMC would be 140-155kg ~$14k supposedly.
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Re: Toyota Hiace poptop conversion

Post by Richo » Fri, 14 Sep 2018, 12:45

So that's $19k and you still need chargers, bms, fuses, wiring, lugs, battery boxes, adapter plates, motor mounts.
and lots of labour.

perhaps all up $25k + labour
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Re: Toyota Hiace poptop conversion

Post by teresah » Fri, 14 Sep 2018, 16:37

Thanks guys for your experience.
My guess is I am chasing a rainbow with this vehicle. Too bad.
Might just have to wait a few more years for dipping my toes in the EV arena
(and still driving Hybrid Camry's for defence fleet).
If anyone has any more cheery news I would like to hear it!

Greg

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Richo
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Re: Toyota Hiace poptop conversion

Post by Richo » Mon, 17 Sep 2018, 12:32

teresah wrote:
Fri, 14 Sep 2018, 16:37
If anyone has any more cheery news I would like to hear it!
Well if you got a 200kW AC motor and 3-4kWh of high performance batteries it would cost about the same.
It may not get to where you want to go bit it would be a crazy drive :twisted:
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