Let's Talk Range! - Suzuki Sidekick 4X4 EV

[@xXZ31t6esTXx]

The gearbox Frankenstein u did should be interesting...

[@scottkahre9206]

Unfortunately, I don't have any pics of it from before I installed it. But, it really worked out pretty simply. I just sacrificed the transmission and used the "tailhousing" as an adapter from the motor face to the transfer case. I knew it was already made on the correct plane, so I just had to locate the holes to match the four motor face bolt holes. It took a little clearancing and a couple of wide washers, but this way I didn't have to make (or pay someone to make) an adapter plate. I cut off the transmission output shaft so I had a piece with the correct spline for the t-case input, then used a 3D printer (at the local library) to make a prototype adapter from the motor shaft to the piece of transmission output shaft. This allowed me to do all the fit-up, then I took it to a local machine shop and had the coupler adapter made from steel and welded to the salvaged piece of transmission shaft. This was the only piece in the entire project that I had to pay someone else to make. It didn't need to be very long to get from the motor to the t-case input, so luckily it came out straight enough to run smoothly at speed. And, so far, the motor torque hasn't snapped it.

[@xXZ31t6esTXx]

@@scottkahre9206 wow a 3d printer in a library? That's awesome! Learning how to design 3d printed pieces is one of my goals

[@shawncell1247]

nice work , hope to see more of it

[@mattw3379]

Thanks for the video! Good information, that 11kwh capacity is whats killing it for range, otherwise amazing setup! Seems with Tesla Modules you could get 200+ miles range but that would be Alot more money.

[@blackterminal]

A huge amount of extra money

[@xXZ31t6esTXx]

How many batteries would you be able to fit? If money was no issue

[@scottkahre9206]

Really no more of the Chevy Volt style without intruding into the inside of the vehicle I've got the engine bay stuffed, and only one fits in the old gas tank skid plate. If you were using a more compact battery design and built boxes sealed well enough to ride underneath along the frame rails, you could probably get close to double what I'm using. But, you might run into weight issues by then, as I already have roughly 400lbs of batteries on board.