XM38E * Electro-Willys

[m38mike]

I just wanted to share some photos of one of my projects. It's a 1952 M38 that's been converted to all electric drive. I took out the gas engine and replaced it with an 11 inch Netgain electric motor. The original flywheel and clutch are still there. So is the rest of the drive train, including the 4wd. It's powered by 18 - 8 volt batteries that create 144 volts. Since these are all deep cycle batteries, they store 23kW of power. It'll run over 65 mph pretty easily, but at that speed it really sucks down the power. All those batteries add over 1,200 lbs to the jeep. And I can only get about 25 miles to a charge. The on-board charger takes about 8 hours to fully charge the battery pack when they are almost completely discharged.

One of these photos shows all the electronic controls that replaced the gas tank under the driver's seat. My intention is to make this jeep a daily driver to commute back and forth to work. I've got an arctic hard top that I plan to put on it for the winter months. One of the comments I get from everyone who's driven it is just how quiet it is. All you hear is the tires crunching on gravel, and the wind, and a little gear whine in the transmission. Other comments include how smooth the ride is with all that weight, and how much power it has. I can spin the tires in 2nd gear on gravel. I can start in 3rd gear from a dead stop. It's a fun rig to drive!

 

[fuzzytoaster]

Dang, what did that setup run you? Looks like it can really run.

 

[uscgmatt]

Thats pretty cool . Do you have a safety cover for the batts?

 

[m38mike]

My cost so far is about $7,000 for the conversion. That doesn't include the basic jeep. What I've discovered is the Flooded Lead Acid batteries are the cheap way to power an Electric Vehicle, but they definitely are not the best. What I'd really like to have are Lithium Iron Phosphate (LiFePO) batteries, but they cost about 5 times what lead-acid batteries cost.

I'm going to put the batteries into two large wood crates that I'm custom making for this purpose. I'll have one crate for the 10 batteries in the back, and one for the 8 batteries under the hood. That'll keep me from dropping tools on the terminals and creating sparks. It'll also help me keep the batteries warmer in the winter.

 

[bratpackdad]

That's cool...next project "electric deuce"

 

[Crazyguyla]

you could always keep in eye out for wrecked hybrids/ electric vehicles at the pick n pull

 

[quarkz]

How heavy is an m38 w/o engine?
What HP is your dc motor.
Kool concept.
And it looks nice too.

Do you cahrge it via the NATO slace cable?

 

[m38mike]

Thanks for the compliments!

I wish there was a "pick and pull" near me. Closest one is about 3 hours away. Not a bad idea though. Might be able to find out by phone if they have the batteries I want.

The M38 w/o engine is about 1,200 lbs, maybe a bit more. My motor will rate at 80 hp, so it's got a bit more zip to it than the gas engine. No I don't have a NATO cable on this one. I use an RV 110v input plug where the gas tank filler neck used to be.

One of the little challenges that I want to try to solve is to see if I can put a generator in my M100 trailer and keep the batteries charged up while I'm driving so I can drive long distances. There are some problems converting 240 VAC to 144 VDC and feeding 18 batteries while you are sucking up to 200 amps out of them going down the road.

 

[TexAndy]

That's cool...next project "electric deuce"

Just think of all the batteries you could fit in the bed...

 

[TexAndy]

You said 8 hours to charge... is that at 110V or 220V?

 

[m38mike]

Ten Col,
I don't think I do. I'll go take a few and post the best of them.

TexAndy,
That's 8 hours at 110v and 15 amps. Just about any outlet is usable. My charger can't use any more power than that.

 

[clinto]

That is just flat out outstanding-looks great, clever engineering, good results, etc.

Thanks for taking the time to share with us.

C

 

[Stretch44875]

 

[Trawler Scott]

I built a M38 that I put some thought into doing this to. I built a very light, strong and great driving willys by using the Willys body on a Suzuki Samurai frame (boxed and galvanized from factory) I used Toyota axles with 4 wheel disc and High steer.
I considered using a M-100 trailer loaded with batteries and running a small generator under the hood for longer range. I ended up with a Toyota 20R and had to sell the Jeep 2 weeks after getting it on the road. I think the setup with trailer for the wieght of the batteries and a genny for range and you could have a nice daily driver.


Scott

 

[m38mike]

Thanks clinto and stretch, I appreciate the compliments.

Trawler, I'm planning on putting a 13kW propane generator in an M100 trailer, along with a 240v 50amp charger, and a half dozen propane tanks to keep me running for extended rides. I've got the batteries in the vehicle so I can disconnect from the trailer for trips under 20 miles.

One of my challenges is to get all this ready for the MVPA Alaska convoy in August 2012. I'm planning on driving this jeep the whole distance. That's a fair challenge for old military iron. That's a significant challenge for an electric drive vehicle! I'm not sure if I'm crazy or just nuts, but I'd like to go back to Alaska, and I'd like to do it in an old Jeep. My first duty station back in the 70's was Ft. Richardson outside of Anchorage.

 

[Marines42]

Thanks for the compliments!

I wish there was a "pick and pull" near me. Closest one is about 3 hours away. Not a bad idea though. Might be able to find out by phone if they have the batteries I want.

The M38 w/o engine is about 1,200 lbs, maybe a bit more. My motor will rate at 80 hp, so it's got a bit more zip to it than the gas engine. No I don't have a NATO cable on this one. I use an RV 110v input plug where the gas tank filler neck used to be.

One of the little challenges that I want to try to solve is to see if I can put a generator in my M100 trailer and keep the batteries charged up while I'm driving so I can drive long distances. There are some problems converting 240 VAC to 144 VDC and feeding 18 batteries while you are sucking up to 200 amps out of them going down the road.

Excellent idea but wouldn't that effectively make it a gasoline vehicle by proxy? I hope you are able to obtain the better batteries. I am interested in seeing what sort of range you can get.

 

[m38mike]

Actually I'm looking at a propane generator. They will operate even when they are moving and bouncing since the entire fuel system is pressurized. Gas generators often have carbs which may or may not function well when they are moving. Diesel gens are injected so they also will work when moving, but they tend to be very heavy. A military 12kW diesel gen set will weigh about 1,000-1,200 lbs. The propane generator I'm looking at weighs in at 250 lbs and it's a 13kW unit. And the propane units are quieter and cleaner burning than a diesel. And the mileage is much better too. A stock M38 will get maybe 20mpg with the gas engine. With a propane generator in a trailer I can get about 30 mpg with the electric motor. So even burning fuel, it's more efficient.

You're right though, better batteries would make a big difference. The flooded lead acid (FLA) batteries I have are the bottom of the totem pole for batteries, but they are the cheapest choice for storing power. When I started this project I was trying to do it just as cheaply as I could. Since then I've learned that cheaper isn't better, and that it is often worth the investment in good quality parts to get what you want. That's why I sold my first controller that cost me $1200 and replaced it with one that cost $1800. Now I've sold that one and will replace it with one that costs $2850. Each change is a measurable upgrade in performance and reliability. For the best in available batteries I need to get lithium iron phosphate (LiFePO). To replace my current pack with the equivalent capacity for energy storage I need 45 LiFePO cells at a total cost of over $9000. I could do that, or I could invest in the generator/trailer. I can't afford both in the next year or two. I think I'll go with the trailer.

 

[maddawg308]

It looks interesting, but it's not for me. Part of the coolness of owning an early jeep is the hum of the L-head engine. With that missing, it's just not 100% jeep anymore.

However, it IS a lot cooler than putzing around in a Prius or other sack-less weenie car. Kinda contradictory though - a war machine that's eco-friendly. I can see the commercial now - DESTROY YOUR ENEMIES while saving the environment!

 

[usmc81301]

I think it would be cool to see a video of this in action!

 

[m38mike]

If you go to this web page and click on the video tab near the top of the page, you'll get to see a video of me driving the Electro-Willys.

EVTV Build Your Dream EV Contest Finalists

maddawg308, Think of it as a VERY stealthy recon machine! There is no noise except the crunch of tires on gravel, and the wind whistling through holes in the windshield. And I guarantee you that it'll outrun any stock gas-engine jeep out there! I've been over 70 with it and had gas pedal left to push.