Thinking of converting a Toyota Hilux

Post by **nat1971a** » Tue, 29 Apr 2008, 20:28

Hi All,

I am thinking of converting a toyota hilux 1988-1995 model with manual transmission ( havent purchased anything yet)and was wondering if anyone can provide advice on the motor.

I am thinking of putting in a Netgain Warp 11 Series wound DC electric motor OR Netgain TransWarp 11 Series wound DC motor -Direct Drive. Can anyone advise on whether the direct drive is an easy and reliable conversion? Or is it safer to got with the 1st motor and adapter plate?

Planned system voltage is 156volts

Design is based on the following conversion http://www.evalbum.com/1450

And can anyone recommend an engineer in melbourne?

Thanks in advance,

Nat

Post by **a4x4kiwi** » Wed, 30 Apr 2008, 00:30

Hi Nat,

Good choice of vehicle, but I am biased.
See my blog for details of my hilux conversion that is about to start this weekend with removing the ICE.

If you want to call and talk about the hilux specifically let me know and I can PM you my number. I am doing an AC conversion so can not help much with the DC side of things apart from battery mounting.

Cheers,
Mal.

Post by **acmotor** » Wed, 30 Apr 2008, 04:06

Hi Nat,
Some thoughts re retaining the gearbox....
It depends on what you are looking for in the way of acceleration and what size motor you use.

Pros of gearbox...
- Lower motor current at take off or uphill (at lower speed).
(battery pack or controller current limit may require this)
- Can make a small motor workable (11inch is not small)
- Option to match the motor RPM better to vehicle speed. Refer to
the motor performance curves.

Cons...
- The gearbox takes up space and is heavy (70kg in the hilux ?)
- The gearbox wastes power. A big point with EVs. They are helically
cut gears.
- In first gear it can be as low as 65% efficient and not likely to be
more than 85% in top gear. You will pay for it in range.
- Personally, I find the gearbox adaptor plate and spline coupling more
trouble than connecting to a tailshaft.

Comments anyone ?

Post by **antiscab** » Wed, 30 Apr 2008, 04:32

if your going to use an 11", use a strong controller such as a zilla 1k or a dcp raptor 1200 or stronger and ditch the gear box.
If you want to retain the gearbox, you may aswell go for a smaller motor, and weaker controller.
If you push 1000A or more through either 11" you run the risk of destroying the gearbox. Just a thought, i dont know for sure how strong the hilux gear box is, but you will find out how strong it is when you break it:p

you might want to consider a internal diff ratio (final drive ratio) of about 4:1, or maybe 5:1. This should give you your 110kmh+ top speed.

have fun with your conversion:)

Matt

Post by **jpcw** » Wed, 30 Apr 2008, 04:40

I'd probably go without the gearbox on a rear wheel drive vehicle if possible. Front wheel drives on the other hand can be a problem as the CV joints etc are probably built in to the gearbox so it's simpler to leave it in.

Post by **nat1971a** » Wed, 30 Apr 2008, 18:27

Thanks for all the great advice. Looks like the consensus is to go without the gearbox. This method sounds the simplest but more costly which is ok as the most simplest method always wins out for reliability. Please correct me if i am wrong here.

Sounds like i will need the cafe electric z2k controller as i was reading the faq (http://www.cafeelectricpress.com/blog/?p=22) on the cafeelectric website and they are recommending anything over 2000lbs (with a direct drive) will overheat a Z1k controller and is best to go for a Z2k.

Can anyone recommend an engineer in melbourne?

Cheers

Nat

Post by **nat1971a** » Wed, 30 Apr 2008, 18:45

@Mal,

I will be watching your conversion very closely. You have chosen well on your vehicle. Very practical. Keep us posted on your progress.

Cheers

Nat

Post by **antiscab** » Thu, 01 May 2008, 05:05

i would go for the zilla 2k aswell, itll give you much better acceleration anyway (assumign your batteries can handle it, optimas and most AGM lead acids can).

Altough it is a little pricey, about $6k by the time you get it over here.
After having a chat with my favourite customs officer, you need to pay GST on the total amount spent inlcuding shipping, and $42.50 fee for customs to process. This is if it comes via Aust post (which the vast majority of USPS does).

Matt