[tlh129]

Good Afternoon Everyone. I am looking to do a project basically just because I want to. I want to convert my 2001 Chevy Suburban 2WD in to a gas/electric hybrid with the following features:

1. Removable battery packs so that I can charge one pack while I am driving on the other.
2. I will settle for a 72V battery system but I really want a 144V battery system(difference of $5K for a LiOn battery system)
3. I have a preference for LiOn batteries.
4. I don't want it to talk to the trucks computer system in v1.0. Therefore I would like to control the electric motor via a pot box or some other type of control to engage and control power to the electric motor.
5. The electric motor can be one of the NetGain models but I am debating on the 9 series or 11 series.
6. Since I won't be able to set up an elaborate braking regen system, I would like to use 2 or 3 extra high output alternators that would work as a generator to recharge the LiOn battery pack when I can't get to a plug fast enough (road trip). I saw a design where a guy on youtube had 5 or 6 connected by one serp belt. He was using it for to charge ultra capacitors for a music loudness competition.

With that being said, I want to ask the group what they think the best option would be out of the following:

1. Since I don't have a 4WD I am thinking of adding a rebuilt/new transfer case with a modification to accept the electric motor instead of where it would normally connect to the front driveshaft. The electric motor would turn the single driveshaft when engaged.

2. Have a transfer case like device built that doesn't require a shift to 4WD but its only purpose would be to give the driveshaft extra power over and above the power coming off the transmission. When not running, the device would spin freely and possibly be disengaged from electric motor. Would you go belt drive, chain drive or gear drive for this device?

3. Attach inline to the driveshaft (via cutting and modifying the driveshaft) as I have seen in many DIY hybrid versions.

4. Replace my front axle with a 4WD front axle that has a front diff and driveshaft connected to it. Instead of that front driveshaft connecting to a transfer case, connect it directly to the electric motor. This would seem to be the heaviest design so I would plan to use the shortest possible carbon fiber driveshaft and a lightweight aluminum cased front differential.

5. I also thought that going into the rear differential from the back of the truck would be a good design but I think Eaton or some other company has already done that and they may have a patent on the design. Also I could not find a company that would do a double-sided rear differential.


In any case, this is more experimental for me than practical so I am not interested in getting the engine from Tahoe Hybrid or downsizing the Suburban and replacing it with a Leaf or going all electric or any other different purchase options that don't involve a solution combining gas and electric in my paid for 2001 Suburban. I just want to do this project and I hope someone out there will be as excited as I am. Thanks in advance.