Wrangler TJ EV Conversion

[4x4 EVC]

So it begins.

We are converting 40 City TJs to all EV.

Our first one is a 2003 Jeep TJ. About 2/3 done but wanted to share were we are.

So much has been done already, I know I should have posted more and more and more but, it's hard when the team is VERY small.

I'll jump in where we are right now.

The Back Battery Box is in and fully finished. It looks like this when out of the Jeep:

It's designed to fit into the exact location of the stock gas tank. There are only three designs we do, CJ, YJ and not the TJ version.

This is mounted using existing bumper bolt locations plus 4 added 5/16" RivNuts into the existing gas tank cross member under the Jeep.

From the back, this is all you'd see:

At the moment, we're working on the Front Battery Box and the Tech Box.

The Tech Box is divided into two parts; the HV-JB and the LV-JB.

NOTES:
- HV-JB = High Voltage Junction Box (144v nominal)
- LV-JB = Low Voltage (12v) Junction Box

Here's a snap with the fender on to work out clearances and stuff:

The cardboard part is the Tech Box and the thing next to it is the Front Battery Box.

My design process is pretty straight forward;
- Cardboard and blue painters tape
- Plywood (if necessary or I have to build stuff that attaches to it)
- Aluminum

I'm under the gun with the City so I'm moving as fast as I can to get this first one done and out the door.

Okay, I'm sure this is enough to wet your appetite, ask anything but if it's insulting, I've learned, it's better to just ignore.

- Patrick

 

[Apparition]

Los Angeles still has 40 TJ's?

I'm interested in what you're doing although I can't fathom any way this makes sense on this scale.

Could definitely see it for an individual who wants an electric TJ though.

 

[speeding_infraction]

 

[Apparition]

Do you have any performance metrics for the design that you could share?

Speeds, battery life, final planned weight etc.

 

[NDSpeed]

That's awesome, as a gearhead the electrification is awesome.

Will you be using motors on each wheel like Tesla? Or utilizing the gear train already there.

Fascinating subject

 

[4x4 EVC]

Los Angeles still has 40 TJ's?

I'm interested in what you're doing although I can't fathom any way this makes sense on this scale.

Could definitely see it for an individual who wants an electric TJ though.

I'll play; why would LA have no TJs? I can't swing a bag of dead cats without hitting 1 (or 5...).

What part aren't you fathoming - please, thrill me with your acumen on scaling?

We don't just do TJs, we also do CJs and YJs - 1976 to 2006 is our wheelhouse.

- Patrick

 

[4x4 EVC]

Do you have any performance metrics for the design that you could share?

Speeds, battery life, final planned weight etc.

Sure, happy to share EVERYTHING you might ponder.

- Speed - much faster then any Jeep should fly.
- About 110 mile range. Off-road is better then highway, which is about 90 miles. 39kW total battery pack and getting around 2.4-2.6 miles per kW.
- Using Tesla Model S battery modules (if anyone cares, I'll be happy to fill you in on the specs of these amazing modules.)
- We were surprised that the final weight is 86 lbs lighter then the stock Jeep. After pondering it for a bit, I figured out that most of that is from removing the bell housing and all it's guts.

I think I answered everything, if you have more, post'um.

- Patrick

 

[4x4 EVC]

View attachment 649369

Funny, I'm kinda' that way also - every day I marvel at what's next. I'm in the show and I can't wait to see what's next!

- Patrick

 

[4x4 EVC]

That's awesome, as a gearhead the electrification is awesome.

Will you be using motors on each wheel like Tesla? Or utilizing the gear train already there.

Fascinating subject

Stock drive train for manual transmission, no bell housing or clutch, we figured out how to get rid of that and still have FULL USE of the transmission and transfercase.

For the automatics, like the City contracted TJs, we are incorporating a reduction unit (fancy words for a planetary gear reduction unit) for the transmission. Haven't gotten to that part of the build, should work, what could possibly go wrong...

The motor, drum roll please, is a Dana - yup, that Dana. One motor that replaces the ICE motor.

- Patrick

 

[Apparition]

I'll play; why would LA have no TJs? I can't swing a bag of dead cats without hitting 1 (or 5...).

What part aren't you fathoming - please, thrill me with your acumen on scaling?

We don't just do TJs, we also do CJs and YJs - 1976 to 2006 is our wheelhouse.

- Patrick

I’m assuming these are for the city of LA, I’m surprised they would still have 20 year old vehicles. I don’t think any cities around here operate anything of that vintage. Crown Vic’s are long gone.

I’m not trying to play, I really like what you’re doing and would love to understand why a city, again I’m assuming that these are the city vehicles, would want to invest the money to retrofit electric vs replace them with modern electric vehicles.

What are these TJ’s used for?

 

[speeding_infraction]

Guessing mail delivery, or parks and rec. Interesting choice to keep a manual, I would've thought there was even less manual drivers than TJ's in LA lol

 

[speeding_infraction]

Funny, I'm kinda' that way also - every day I marvel at what's next. I'm in the show and I can't wait to see what's next!

- Patrick

Well, I posted that gif because I thought you would've got roasted alive by the members - only a little bit glad to see that wasn't the case

Have you heard of Edison motors?

 

[Apparition]

Looked at your site, impressive that it’s all modular and reversible.

 

[Lou]

I’m assuming these are for the city of LA, I’m surprised they would still have 20 year old vehicles. I don’t think any cities around here operate anything of that vintage. Crown Vic’s are long gone.

I’m not trying to play, I really like what you’re doing and would love to understand why a city, again I’m assuming that these are the city vehicles, would want to invest the money to retrofit electric vs replace them with modern electric vehicles.

What are these TJ’s used for?

Long Beach has a ton of RHD TJ’s for parking enforcement. They reach out and mark the tires of your car in time limited zones.

 

[Apparition]

Long Beach has a ton of RHD TJ’s for parking enforcement. They reach out and mark the tires of your car in time limited zones.

I have to remember that these things last longer where you live too.

 

[B1Toad]

What's going to happen with all the old engines, parts and running gear?

 

[Lou]

What's going to happen with all the old engines, parts and running gear?

I would not want to buy a used engine off a parking enforcement vehicle that’s 20 years old haha

 

[speeding_infraction]

Looked at your site, impressive that it’s all modular and reversible.

Not my site, I just happen to watch them on YouTube. Certainly a crazy amount of R&D has gone into that project, I'm sure yours is the same way.

 

[Apparition]

Not my site, I just happen to watch them on YouTube. Certainly a crazy amount of R&D has gone into that project, I'm sure yours is the same way.

Not your site, the OP’s site.

 

[4x4 EVC]

I’m assuming these are for the city of LA, I’m surprised they would still have 20 year old vehicles. I don’t think any cities around here operate anything of that vintage. Crown Vic’s are long gone.

I’m not trying to play, I really like what you’re doing and would love to understand why a city, again I’m assuming that these are the city vehicles, would want to invest the money to retrofit electric vs replace them with modern electric vehicles.

What are these TJ’s used for?

You're not wrong. They are purpose used. I'm not free to expand on that part. Not right now anyway.

Mostly stock.

- Patrick