Why not develop an axel with an integrated motor? It’d be easily scaled to any vehicle with a solid rear axle. Fill the engine bay with batteries… It seems like an easy approach to get a widely applicable EV conversion kit. Offer a few widths and diameter axles… Is it bad to have the motor in an unsprung position?I see hub motors, so I think not. I guess air conditioning would be another thing.
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A diff head replacement EV motor would be an interesting idea. The amount of unsprung weight would be less than ideal though. It’s probably a better idea to have a motor that sits in the trans tunnel and connects to the transfer case.
Because the market is the dozen people on this subreddit…
Or prop shaft hybrid kits, with an inline motor and a shortened driveshaft to the rear axle.
For that matter, a motor/differential assembly that used cv shafts to fit whatever the application is would be fairly easy.
I figure replacing an axle would be the simplest approach. I don’t know about inline motors and all that.
It’s been done. Not the best solution, but not a terrible idea, either. Airstream introduced a prototype electric model with powered axels, offset the energy needed to pull the trailer, added the ability to regen, and added the ability to self-park into an RV slot.
Make one and sell it. I’d buy
Electric tuk tuks use a custom center section with a motor bolted directly into a standard axle. The kits cost less than 500 if you go looking.
Whats needed is the same situation for noth American axels. What jumps to mind is the ford 9 inch since it has the same front facing center section. Some old dodges were the same i dont think chevy ever had a front facing center sections but its just a clearance clarance issue.
Its doable. The first shop to start melting soda cans to cast them cheap is gonna make a million in the diy market.
Most likely because higher-end EV swaps use Tesla rear drive units, which are fairly plentiful.
We’re starting to see commercial-off-the-shelf subframes for putting Tesla motors in classic trucks.
For example:
https://www.aemelectronics.com/products/ev_conversions/conversion_brackets/parts/HEV002-001
I have been looking into this exact question. All of the Tier 1 OEM suppliers have some kind of integrated Axle option. Manga, Allison, etc. the next big hurdle is integrating all of that with the existing controls and everything else. Manga did a drop in swap for a GMC Sierra 3500 as a proof of concept. I think there is a huge market if someone does the engineering and solves the interface and fitment issues. You could probably sell the kit to all the class 4 and class 5 vehicle upfitters. Feel free to DM me if you want to talk about it. I think it is a good business, i have experience supplying the Tier 1’s with metals. Specifically aluminum so i have a decent idea of how it works but not an on the ground installers view. I would like to follow the road map that Edison motors has written for the class 8 vocational and heavy haul market.
Why not the best of both worlds? ICE up front, electric motor in the axle with a supercapacitor bank as a “battery”
I think I’d rather have a series hybrid like they’re using in the Edison trucks. Ideally it could also power some of my house during a blackout.
You are basically describing the Jeep 4xE / Mitsubishi Outlander phevs
The LDV ET60 has it’s motor attached to a live rear axle, it handles like a dog because of all the unsprung weight.
Koenigsegg Quark
It’s not exactly the same, but check out what Edison motors is doing. They are purchasing ready-built electric axles to replace the motor/gearbox on future incarnations so somebody is making them for commercial truck chassis.
There are, for trucks. Magna makes one called the e-Beam.
I’ve seen a kit for a Range Rover that looked pretty cool.
But a generic axle swap means someone has to figure out how to adapt the suspension to the new axle. Which means custom mounts and some welding which might make the manufacturer worry about liability of the axle comes loose on the highway.
I think an eclectic motor sitting where the transmission used to be would be far easier for a DIY swap and cheaper.
The downside to putting the motor where the transmission was is that all the old ICE drive train can’t handle the instant torque, or the torque in general of most EV motors. That motor would likely shred the differential and the drive shaft.
If you look into it, you’ll find that something like a Wrangler Rubicon can actually produce more torque thanks to crazy low gearing. It can only do it at speeds so low that it is only useful for off road rock crawling at a walking pace, but it does it it with drive shafts and differentials that aren’t very special and don’t explode.
I figured axles generally only vary in width and diameter. Spring perches and other suspension attachment points can be easily welded on. Basically use the stock suspension. My little Suzuki uses leaf springs, so it’d be very simple.
There would also be some issues with the wheel flange if you want it to match the other axle and the brakes if you want them to continue to work.
But I think the biggest problem would be the the manufacturer worrying about you and me welding it badly and them getting a share of the blame when it comes loose on the highway and takes out a bus full of nuns and orphans.
It’s still early days. In a few years there will be a huge range of choices for different systems and kits. I say give it time. Or build and sell one yourself!