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E CONVERSION

broncobusted

Full Member
Joined
Aug 12, 2013
Messages
247
Hello everyone in bronco land. I hope all are well. I just wanted to ask if anyone has had experience with converting an old bronco to electric drivetrain. I recently went down this rabbit hole on you tube and I thought it would be best to ask the bronco experts. I have a 69 and am just looking for any input. Thanks for any response.
 

fordguy

Contributor
Bronco Guru
Joined
Jan 23, 2005
Messages
5,847
Iron Resurrection folks visited a shop in Texas that specialized in converting older cars like muscle and street rods. You might find some info on drivetrain there. I dont remember the name of the company.
 

Broncobowsher

Total hack
Joined
Jun 4, 2002
Messages
35,684
Done years ago. Several at SEMA back in 2021.
Shown and sold at Barrett Jackson as well.
Motor, inverter, controller, sold be a company called Torque Trends.
Divorced Atlas transfer case.
Batteries are the biggest issue. Cost, packaging, wear...
 

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904Bronco

Contributor
Bronco Guru
Joined
Sep 28, 2004
Messages
6,022
Loc.
San Martin, CA
Done years ago. Several at SEMA back in 2021.
Shown and sold at Barrett Jackson as well.
Motor, inverter, controller, sold be a company called Torque Trends.
Divorced Atlas transfer case.
Batteries are the biggest issue. Cost, packaging, wear...

I asked, they had two battery packs available... You would be looking at a 300 mile travel distance with the more expensive package. They were, at that time, providing training to help you install their product...
 

Broncobowsher

Total hack
Joined
Jun 4, 2002
Messages
35,684
Here's the Kinser unit that was at SC last year!! :) :) :)
That one was also at SEMA 2 years ago. Same powertrain.
The motors that Torque Trends use are originally for bus conversion. 250kw, which is about 350HP. But you have to counter that with a LOT of HEAVY batteries. I've also seen the motors used in boats. They can take lots of sustained, heavy loads.
 

duffymahoney

Contributor
Bronco Guru
Joined
Apr 26, 2015
Messages
2,641
I think they all had issue with hiding the batteries. Looks like 85kw in that kincer battery. Which isn't terrible at all.
 

MarsChariot

Contributor
Planetary Offroader
Joined
Oct 12, 2004
Messages
2,522
Loc.
Albuquerque, New Mexico
As I recall the principal problem with these, at leasy currently, is $200k ± cost. You would need to be very well off to partake of this option right now. Otherwise it sounds like it is getting close to the right mileage.
 

Broncobowsher

Total hack
Joined
Jun 4, 2002
Messages
35,684
Correct, parts are not cheap. It would take a lot of creativity and a bit of good luck sourcing parts from wrecked cars to keep a good build to the low 6-figure mark.

There isn't a lot of donor material for beam axle trucks out there. Most everything is based on a motor and gearbox as a combined unit. There are some RWD car retrofit kits using a Tesla motor and I don't remember what for a transmission. Designed to bolt right in place of the standard engine and transmission. Never seen one of these that could take 4WD and a divorced transfer case just doesn't package into a Bronco typically. I have never looked at one, but the new Jeep 4xe might offer up a good usable 4WD powertrain. They are too new and rare at the moment. But give it 5 years and you will probably start finding drivetrains from wrecks and aftermarket support to make it run without all the intertwined modules.
 

duffymahoney

Contributor
Bronco Guru
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Apr 26, 2015
Messages
2,641
Because of all the Porsche and VW Tesla swaps going on, the market for used motors and batteries is ludicrous. Driving a 3 sec 0-60 VW bug sounds terrifying and awesome.
 

Digger556

Sr. Member
Joined
Aug 8, 2013
Messages
797
Hello everyone in bronco land. I hope all are well. I just wanted to ask if anyone has had experience with converting an old bronco to electric drivetrain. I recently went down this rabbit hole on you tube and I thought it would be best to ask the bronco experts. I have a 69 and am just looking for any input. Thanks for any response.
One factor that's hard to get around is the brick-like aerodynamics of the Bronco. At low speeds, this is less of a factor, but driving above 45mph, aero losses will require more powerful motors the faster you want to drive, and battery capacity will need grow significantly. My rig is not the best example being lifted on 37s, but it takes 75-95 hp to push it down the road at 75mph depending on the wind direction.

85 hp is 64kw of shaft power. Motors are ~90% efficient combined with a controller that is ~95% efficient, requiring 74.5 kW from the battery.(There are many other sources of losses, but let's ignore that for now.) The largest Telsa Model 3 battery is 82 kWh and assuming a max depth of discharge of 80% for Li-Ion chemistry, the power available from the battery is 65.6 kWh, giving you a driving range of 66 miles compared to 300-400 miles for a Tesla.

Lower speeds will result in better range or smaller batteries, but you get the idea.
 

Broncobowsher

Total hack
Joined
Jun 4, 2002
Messages
35,684
Hoovies Garage on YouTube had a Lightning for a little bit. The towing stuff shows what a little extra drag can do to an EV range. The truck is modern, spent more development time in a wind tunnel than many older aircraft. Everything is optimized as much as possible. An empty flat bed car trailer ate the range.
 

Scoop

Contributor
Have Bronco, Will Travel
Joined
Feb 1, 2006
Messages
10,814
Loc.
Cuchara, CO
I'd love to have an EB converted to electric for short trips into town. The "big cities" for me - where I can get to a Sam's or a Lowes or a Walmart - are 70 miles away. So a round trip of say 150 miles would be needed. But then throw in the cold weather here 6 months of the year which reportedly drops the range by 40-50% I'd need a setup with about 300 miles optimum range. I don't think that's achievable with today's technology and the size of battery you can fit in a Bronco.

I would not be doing this to save the world but for convenience of being able to charge at home. My daughter has a plug in hybrid and she charges it here when she visits. Her electric mode range is 50 miles and she lives about 120 from us.

I think a really cool new electric vehicle is the Manx 2.0 EV. Probably better aerodynamics than an EB but wouldn't help me out in the winter!!

535ECA38-C001-4112-8FD3-E85D3FABA99F_4_5005_c.jpeg
 

bigmuddy

Contributor
Bronco Guru
Joined
Dec 28, 2004
Messages
7,362
Loc.
Marthasville Missouri
Which brings up a point and conversation I have been throwing out lately as it's bugging me.
With the current administration pushing for quicker draw down on the use of the combustion engine and the auto manufacturers making claims that they will not make combustion engine vehicles available in the near future, how long does it take before we cannot get fuel or fuel is priced out of our reach and out loving broncos are big paper weights?
To that end, I can't get my head around parts companies becoming more valuable or less valuable to combustion engine vehicles in the near future? Hard to get parts? Parts are obsolete and no longer being produced.

Hell, how will it work when Ford or other another auto producer comes out and says I'm not making any more combustion vehicles after 2035 or whatever date? and then for how long will you be able to get replacement parts for the new vehicle and how bad does a new combustion engine type of vehicles worth be eroded?

Sounds a bit paranoid but it really gets me going...
 

Broncobowsher

Total hack
Joined
Jun 4, 2002
Messages
35,684
A lot will depend on what happens in 2024

But that is a political rabbit hole that will push this thread into an off-topic. Someone else can start that one so I can ignore it.
 

bigmuddy

Contributor
Bronco Guru
Joined
Dec 28, 2004
Messages
7,362
Loc.
Marthasville Missouri
A lot will depend on what happens in 2024

But that is a political rabbit hole that will push this thread into an off-topic. Someone else can start that one so I can ignore it.
I don't disagree and I don't want to get political, but you can't ignore that there a large group pushing toward full on e vehicles....
 
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