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Old 07-11-2021, 12:56 AM   #1 (permalink)
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Best way to build a hybrid truck?

I really, really want a 1/2 ton plug-in hybrid pickup truck. First, I want all the engine accessories to be electric. No alternator, just a battery pack. Relatively simple to accomplish.

Second, I want the front wheels to be electrified. It doesn't need to go very fast, just for creeping along in traffic, parking lots, drive thrus, etc with the engine off. It could also provide regenerative braking at higher speeds.

If I start with a generic 1/2 ton 4WD truck (I'm not naming a brand on purpose) what would be the best way to try and accomplish this? I would like to get rid of the transfer case but keep the front axle.

What size motor would I need to do such a thing? Could I do something as simple as attaching a ~10hp electric motor to the front driveshaft, or directly on the differential? I'm not really sure how much power I would need, or what options are out there. I would prefer to keep the whole thing running on 48v if I can...

Thoughts?

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Old 07-11-2021, 02:21 AM   #2 (permalink)
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Welcome to Ecomodder. Jumping right into the deep end of the pool?

Consider the ways to your goal.
  • A mild hybrid would have an altermotor on the internal combustion engine. Easiest but no creeping around parking lots.
  • A conventional hybrid would put an electric motor in the drivetrain. Prius and Chevy trucks integrate into the transmission. Aftermarket units replace a tailshaft.
  • Replacing a transfer case with an electric motor creates a through-the-road hybrid with two separated powertrains.

Bolting a motor directly to a solid axle would be sub-optimal.

Have you looked around here much? Here's the altermotor: ecomodder.com/forum/showthread.php/controller-mods-build-e-assist-altermotor-35003.html. 15-20 horsespower at 55 to 72 Volts.

And here's an electric axle: ecomodder.com/forum/showthread.php/hot-rodding-toyota-mgr-29878.html. 98 pounds and 68 horsepowers.

I actually have a Lexus axle, but it wants higher voltages, maybe 400V.

The actual build process would start with a scoping statement and use case.
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Old 07-11-2021, 04:41 AM   #3 (permalink)
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This is something I have been thinking about for a very long time. Technology is changing so fast it's kind of hard to keep up. Much of it is for convenience and reliability as much as it is for gas mileage. I want to be able to "idle" with the engine off. By that I mean heating or A/C, lighting, or creeping forward. I don't want any belt system on the engine, and it would be useful to be able to run electric water pump and fan with the engine off, or maybe a block heater depending on weather.

There will be an additional gas powered DC generator in the 3-4kw range installed in a toolbox in the bed. Obviously a battery pack, not huge, hopefully around 10kw, and it will also have a 10kw power inverter so it can be used as a mobile generator. With that I can also power 120v accessories like a block heater or air conditioning.

What kind of motors are available that mount to the trans tailshaft? If I did something like that I could simply use a lighter 2WD truck right? (I don't need to go off road) I will likely be using a 4L80E for a trans unless I decide I want more gears. I know GM did it like that but I figured they are kind of rare and hard to find parts, but maybe I'm wrong.

Basically I am building a "new" 20-ish year old truck because I absolutely hate all the new stuff. Maybe it would be easier to just get the factory GM hybrid and make it as nice as I can, but probably not easy to find. I do not want something that has rare and hard to replace components.
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Old 07-11-2021, 05:35 AM   #4 (permalink)
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When I think of a 1/2-ton truck, it's usually a bobber*.



Have you considered a pure EV? Once you factor in air conditioning** and vehicle-to-grid, the battery requirement is way North of 10kW.

First two results at duckduckgo.com/?q=electric+motor+replace+transmission+tailshaft

Quote:
electric car parts conversion motor warp impulse netgain ...
electric car parts conversion motor warp impulse netgain series DC
transmission. In other words, this motor was designed to replace a transmission and couple directly to a drive shaft! ... This motor has a "shorty" tail shaft housing from a Chevrolet Turbo 400 transmission ... By utilizing a 12 volt electric pump that can deliver 2 to 3 gallons per minute, and ...

The Free Energy Store electric car motor, global electric ...
The Free Energy Store electric car motor, global electric motor car, club car electric motor, car electric hybrid motor toyota, electric golf car motor, car dc electric motor, general motor electric car, car electric kit motor, electric car conversio
This motor has a "shorty" tailshaft housing from a Chevrolet Turbo 400 transmission fitted to the drive end-bell (may be ordered with or without housing!) This is becuase the drive end shaft is not the typical 1.125" single-keyed type, but rather a hefty 1.370", 32-tooth involute spline that is identical to the tailshaft spline of a Turbo 400 ...
Information‧Order‧Products
What would you think of a Rabbit or Dodge Rampage front-wheel drive pickup with the altermotor, and a pure EV conversion under the bed? Sorta you like hybrids so you put an hybrid in your hybrid so you could hybridize while your hybrizating?

And an aerocap that opens into a solar collector.

* ecomodder.com/forum/showthread.php/1946-chevy-prius-truck

** ecomodder.com/forum/showthread.php/electric-ac-compressor
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Old 07-11-2021, 05:48 AM   #5 (permalink)
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I would love a totally electric pickup but I think right now the parts are just too expensive and I don't want a giant battery bank. The engine will be a 400-ish HP GDI V8, built with efficiency in mind...not going to win any awards for MPG but it shouldn't be bad if driven carefully. (Cutting out almost all idling would definitely help that)

It will be a single cab short bed, so it only weighs about 3700lbs in stock form. I really don't need a big electric motor, I don't see using it over about 10mph.
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Old 07-11-2021, 01:45 PM   #6 (permalink)
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funkhoss got his station wagon to 46 50 MPG. Check the drivetrain section of the first post: ecomodder.com: 94 Caprice Wagon project--now 50.55 MPG with "3/4 ton" drivetrain/suspension
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Old 07-11-2021, 05:48 PM   #7 (permalink)
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Quote:
Originally Posted by 48V View Post
I would love a totally electric pickup but I think right now the parts are just too expensive and I don't want a giant battery bank..
Fords $35,000 F150 Lighting is likely a better option
Also from Ford is the $20000 40mpg Maverick pickup

Trying to convert an existing truck will be
Very Expensive
Very unfortunate and hill billied
Or both

The only working plug in Hybrid truck that is somewhat available is from GM and it’s partners but you have to find a used one

Ben made a hybrid truck from an s10 with a Mercedes diesel 5mt + a separate dc series double shaft motor to run the rear axle electrically for a short distance

https://ecomodder.com/forum/showthre...uck-22080.html

The workable DIY method of making a Chevy Volt pickup would be to convert a rolled Volt into a truck similar to this

https://ecomodder.com/forum/showthre...uck-34935.html

There really are no inexpensive or “good ways” of diy Hybrid without re-using a full OEM solution

Last edited by rmay635703; 07-11-2021 at 06:20 PM..
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Old 07-11-2021, 06:28 PM   #8 (permalink)
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$35K is a pretty high bar.

Any VW, Jeep, Audi, Subaru or Dodge hybrid could become a ute: www.smythkitcars.com/

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Old 07-11-2021, 08:58 PM   #9 (permalink)
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AFAIK the only parts supplier trying to develop a 48-volt full-hybrid setup is Valeo, but it's more focused on light-duty vehicles.
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Old 07-12-2021, 12:01 AM   #10 (permalink)
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Quote:
Originally Posted by rmay635703 View Post
Fords $35,000 F150 Lighting is likely a better option
Bull****. I've explained some things very clearly but let me be more blunt:
1. I am building a nice, expensive American pickup truck. I am not driving an embarrassing MPG mobile. Nor a wagon, or whatever other ridiculous stupid thing you dig up.

2. I've explained I absolutely do not want anything new. If you gave me a brand new truck, and paid the taxes for me, I would sell it and buy an old one.

3. I never said I wanted a full hybrid. The "mild hybrid" part is really easy. Electric fans/water pumps/AC is child's play in 2021. I can literally buy all this stuff straight out of a Summit catalog and it's designed to bolt up to my engine. And it cost almost nothing.

4. As far as movement is concerned, I want less than 10mph. That is not a big ask. There are many different ways this could be accomplished, I was simply curious if anybody else had done it. Obviously that takes very little HP, and thus, 48v would be absolutely fine. Maybe even 24.

5. I already explained I do not care about gas mileage. I want a truck that is functionally superior, I couldn't care less how much gas it uses. In fact, it will be getting a 100 gallon tank. Again, as I already said, this truck will be a mobile generator, and has features that are nicer than you will find in something from the factory. There are other reasons for hybridization beyond saving a few cents worth of gas.

6. I'm not poor. I could go to the dealership and take any car they have. Again, I have not seen any current models I want anything to do with. Thus, I make the car I want. Not my first rodeo.

I'm sure this conversation is over (to be fair it never started) so I won't bother checking this any further.

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