Does anyone use a powerglide transmission? 2 speed planetary, known for being super strong with tons of aftermarket support.
Wrangler TJ EV Conversion
- Thread starter 4x4 EVC
- Start date
Does anyone use a powerglide transmission? 2 speed planetary, known for being super strong with tons of aftermarket support.
Something like a jerico 2 speed would be easier. Lots of configurations and low cost
https://www.jericoperformance.com/2speed.html
It's a legendary transmission, to be sure but, once again, it's still a hydrostatic component, albeit a geared flavor. The thing that keeps it going is to have some form of hydraulic pressure and that's not a thing in the EV world.
If you start from the ICE propositions that the motor is always running to used, everything after that incorporates that into the calculus.
BUT, if I was a smart engineer, I'd sure as shit use it as a guide for what could be a 2-speed solution - super interesting idea @srimes!
- Patrick
Yeah, maybe that.
Interesting. I don't think it's synchronous though.
Whatever, interesting idea.
- Patrick
I'm working on this part of the Tech Box:
I need to get the Power IN to the Tech Box to branch off to +B and -B on the Inverter.
If you scroll back up, I put a diagram showing the layout.
Here's the parts that make up most of that, graphic view to see what I'm working on:
- Patrick
I need to get the Power IN to the Tech Box to branch off to +B and -B on the Inverter.
If you scroll back up, I put a diagram showing the layout.
Here's the parts that make up most of that, graphic view to see what I'm working on:
- Patrick
Just to float this in case it hasn’t been considered, Advanced adapters makes a 1:1+2 speed under drive unit called the rubicrawler for the 42RLE/231
Yes, that is also interesting but, I think less OEMy - you have to basically stop to shift, if I read this correctly.
BUT, absolutely worth the effort to call Advanced Adapters when this build is done.
Very interesting.
Maybe, I wonder if you'd have to stop to shift if we did the same thing we do with manual transmissions and program in a 'motor' rpm to follow a similar path to idle speed.
Yep, gotta' give them a call later.
Thanks for that,
Patrick
Bus Bar pictures - all from the Tech Box.
Custom bent bus bars
Looking down into the Tech Box
Another view, more completed in this pic.
Alright, back to work, that C110 won't bend itself!
- Patrick
Custom bent bus bars
Looking down into the Tech Box
Another view, more completed in this pic.
Alright, back to work, that C110 won't bend itself!
- Patrick
Alright, so where I am in this build is here, working on the Tech Box, here it is.
If you go back a couple pages, I put a basic diagram of the Interconnects (this usually refers to moving power, DC mostly, from point A to point B.).
This box will have the bulk of the LV (Low Voltage) wiring in it also. Things missing on the outside are the LV master Sw., about 6 flanged connectors to deal with Jeep stock PDC (Power Distribution Unit) wiring, maybe a fan to keep airflow in the Tech Box. Also, have to hook up the HV 'small' stuff - A/C, OBC-DC/DC Charger, internal Precharge.
The Tech Box, our first in this size/format, always takes a bit of time. All together, about 9,000 wires and connectors (slight exaggeration...).
I'll try to post updates with a bit more frequency.
- Patrick
If you go back a couple pages, I put a basic diagram of the Interconnects (this usually refers to moving power, DC mostly, from point A to point B.).
This box will have the bulk of the LV (Low Voltage) wiring in it also. Things missing on the outside are the LV master Sw., about 6 flanged connectors to deal with Jeep stock PDC (Power Distribution Unit) wiring, maybe a fan to keep airflow in the Tech Box. Also, have to hook up the HV 'small' stuff - A/C, OBC-DC/DC Charger, internal Precharge.
The Tech Box, our first in this size/format, always takes a bit of time. All together, about 9,000 wires and connectors (slight exaggeration...).
I'll try to post updates with a bit more frequency.
- Patrick
Progress, obviously...
(you might need to squint, but progress is there, somewhere, probably under that thing on the left...)
Working on wiring. You get all these harnesses and you have to make connector decisions based on where the source of the wire is and where the final destination of the intent of that wire is.
You end up cutting and assembling connectors based on what will hook up inside the Tech Box, what's outside, where's the components pig-tail (we add pig-tails for the LV stuff for ease of installation / repair). Takes forever the first time. Constant second guessing and trying to imagine what will go around it and will it see exposure to the elements, does it need additional split loom, how to make a bracket to hold the connector, etc., etc., etc.
I really like this part but, it's a lot of crap floating that has to eventually solidify into a nicely bound and secured harness.
Stuff.
- Patrick
(you might need to squint, but progress is there, somewhere, probably under that thing on the left...)
Working on wiring. You get all these harnesses and you have to make connector decisions based on where the source of the wire is and where the final destination of the intent of that wire is.
You end up cutting and assembling connectors based on what will hook up inside the Tech Box, what's outside, where's the components pig-tail (we add pig-tails for the LV stuff for ease of installation / repair). Takes forever the first time. Constant second guessing and trying to imagine what will go around it and will it see exposure to the elements, does it need additional split loom, how to make a bracket to hold the connector, etc., etc., etc.
I really like this part but, it's a lot of crap floating that has to eventually solidify into a nicely bound and secured harness.
Stuff.
- Patrick
Okeydokey, here we go, mo' progress.
I'll try to go in some sorta' order but, you know, stuff...
Also, try to remember, everything we do here, has to have a production run purpose to it. What does that mean? Nothing can be one-off. Everything has to easily and technically be repeatable and not just by me or a trained EV installer. No, can't do that - all things have to have a modularity an average Jeep mechanic with a decent tool box and a cherry picker can install.
If you can install a motor and get it to turn over, then you should be able to install one of the eventual retail kits into your own Jeep, with the help of Jim, you're neighbor, the one with all the new tools and the kinda' flirty wife, that guy.
So keeping that in mind, we don't build one-offs and we don't get caught in garages alone with Jim's wife, as if I had to say that out loud.
Onward...
Moving the wiring harness from the wiring bench (see last post) to the Tech Box means that I've finished breaking down some of the wiring harnesses. Here's what that looks like this ridiculous 86deg Nov 9 winter day in Los Angeles - who loves global warming - ME!!!
I've also finished the reconfiguration of the stock engine bay Jeep wiring harness and the PDC (Power Distribution Center). Mostly removing (depining, never cutting) the things like O2 sensors, starter relays, various sensors (engine temp, MAP, TPS, etc.). I'm not in love with this bussed fuse block but it works for now. The alternative is 100% custom and I'm out of time for that nonsense, at least for now.
One of the big things is making sure the stock Jeep functions work, you know, brakes lights, IGN key stuff, radio, blower, all that things that have to keep working despite the open-heart surgery. Here's a quick video:
Here's where the Tech Box is going to fit.
Have I mentioned that all EV conversion comes down to bracketing, never ending bracketing.... Here's a mockup of the brackets that will carry the HV Cables, 3 coolant hoses and the J1772 (charge port) harness from the back of the Jeep to the front where are the action is. One of the hardest things about making brackets is figuring out how it will actually assemble and fit in the Jeep. Many a brilliant design goes down in flames when you figure out that you've made it impossible to screw something to something around something connected to something that you didn't think about till now....why do bad thing happen to good people?!?
This design works, at least in cardboard and blue tape. I'll follow up when I make it out of AL (for all you crackers out there, 'AL' means aluminium AND Alabama, who would have thunk it!).
I know there's a ton of questions and I equely know I could be more informative, like the Jeremys (Jeremy Makes Things (link: and Jeremy at Electric Supercar, link: https://www.youtube.com/@electricsupercar ) - I don't know how they do it, I can't even be bothered with editing, sorry.
Back to it!
-Patrick
I'll try to go in some sorta' order but, you know, stuff...
Also, try to remember, everything we do here, has to have a production run purpose to it. What does that mean? Nothing can be one-off. Everything has to easily and technically be repeatable and not just by me or a trained EV installer. No, can't do that - all things have to have a modularity an average Jeep mechanic with a decent tool box and a cherry picker can install.
If you can install a motor and get it to turn over, then you should be able to install one of the eventual retail kits into your own Jeep, with the help of Jim, you're neighbor, the one with all the new tools and the kinda' flirty wife, that guy.
So keeping that in mind, we don't build one-offs and we don't get caught in garages alone with Jim's wife, as if I had to say that out loud.
Onward...
Moving the wiring harness from the wiring bench (see last post) to the Tech Box means that I've finished breaking down some of the wiring harnesses. Here's what that looks like this ridiculous 86deg Nov 9 winter day in Los Angeles - who loves global warming - ME!!!
I've also finished the reconfiguration of the stock engine bay Jeep wiring harness and the PDC (Power Distribution Center). Mostly removing (depining, never cutting) the things like O2 sensors, starter relays, various sensors (engine temp, MAP, TPS, etc.). I'm not in love with this bussed fuse block but it works for now. The alternative is 100% custom and I'm out of time for that nonsense, at least for now.
One of the big things is making sure the stock Jeep functions work, you know, brakes lights, IGN key stuff, radio, blower, all that things that have to keep working despite the open-heart surgery. Here's a quick video:
Here's where the Tech Box is going to fit.
Have I mentioned that all EV conversion comes down to bracketing, never ending bracketing.... Here's a mockup of the brackets that will carry the HV Cables, 3 coolant hoses and the J1772 (charge port) harness from the back of the Jeep to the front where are the action is. One of the hardest things about making brackets is figuring out how it will actually assemble and fit in the Jeep. Many a brilliant design goes down in flames when you figure out that you've made it impossible to screw something to something around something connected to something that you didn't think about till now....why do bad thing happen to good people?!?
This design works, at least in cardboard and blue tape. I'll follow up when I make it out of AL (for all you crackers out there, 'AL' means aluminium AND Alabama, who would have thunk it!).
I know there's a ton of questions and I equely know I could be more informative, like the Jeremys (Jeremy Makes Things (link: and Jeremy at Electric Supercar, link: https://www.youtube.com/@electricsupercar ) - I don't know how they do it, I can't even be bothered with editing, sorry.
Back to it!
-Patrick
It's been a tick....
Quick walk though of the 2003 Jeep TJ EV conversion work.
Let me know if you have any questions.
- Patrick
View: https://youtu.be/IsMrED9KU8o?si=yvOQ8UzAaSoqpZHl
Quick walk though of the 2003 Jeep TJ EV conversion work.
Let me know if you have any questions.
- Patrick
View: https://youtu.be/IsMrED9KU8o?si=yvOQ8UzAaSoqpZHl
I wish there was a lot more information than "we did some stuff and the motor spins both ways".
Wait, wait, here's more snippet info completely out of context:
Hay, just got my Guchen A/C to turn on and respond to all commands via Arduino program we wrote.
I was afraid it would jump off the table but it was as gentle and quiet as the water pump!
- Patrick
Hay, just got my Guchen A/C to turn on and respond to all commands via Arduino program we wrote.
I was afraid it would jump off the table but it was as gentle and quiet as the water pump!
- Patrick
Yes, of course, my fault.
I've been running out of time so I decided to greatly curtail my social stuff and ended up with the least technical forum that would just keep in somewhat connected - JeepForum Breakfast Club.
Might be faster to do a more in-depth video to catch up on all the part that we're working on rather than try to cobble all the smaller stuff together.
Also, that gives me fresh stuff on here that might be of interest to you guys but not to others.
- Patrick
Hello All,
Bumping around the Jeep Shop, taking in proportional amounts of coffee, banana, power bar and biscotti - you know, all the while thinking about the perfect perfect butter delivery system AKA: Grits, so I can choke all this other stuff down...
Anyway, the City TJ is coming along, all the large engine bay stuff is in now. Much of it hooked up also. Here's a photo of the work we are doing on the A/C and the new PDC (Power Distribution Center - super dumb name):
The last 3 major things to complete are:
- Adapter from TC to TouqueTrends reduction unit - this is the the thing that steps in to take the place of an automatic trans.
- A/C complete control set up - pre-charge, start, stop, RPM
- A/C plumbing - route decide and parts obtained, just having a trained A/C guy do all the work the first time so I can learn how to do it.
- EPB - Electric Parking Brake from Wilwood - we have to do a drum to disc conversion on the back then we can add the EPB back plate to hold the locking calipers to the rotor
I'm happy but behind.
- Patrick
Bumping around the Jeep Shop, taking in proportional amounts of coffee, banana, power bar and biscotti - you know, all the while thinking about the perfect perfect butter delivery system AKA: Grits, so I can choke all this other stuff down...
Anyway, the City TJ is coming along, all the large engine bay stuff is in now. Much of it hooked up also. Here's a photo of the work we are doing on the A/C and the new PDC (Power Distribution Center - super dumb name):
The last 3 major things to complete are:
- Adapter from TC to TouqueTrends reduction unit - this is the the thing that steps in to take the place of an automatic trans.
- A/C complete control set up - pre-charge, start, stop, RPM
- A/C plumbing - route decide and parts obtained, just having a trained A/C guy do all the work the first time so I can learn how to do it.
- EPB - Electric Parking Brake from Wilwood - we have to do a drum to disc conversion on the back then we can add the EPB back plate to hold the locking calipers to the rotor
I'm happy but behind.
- Patrick
And this underscores the problem with EVs as practiced. Why are you insisting on more electric crap? Use the mechanical brake the TJ already has - one less thing to go wrong and one less hassle/expense to deal with...
We are going to change our strategy up a bit and try to focus on the TJ Kit first and to be be done and starting to deliver this year.
The plan, (I laugh as I type that word...), the plan is to get this first TJ done with a donner TJ to keep as the proof/demo TJ and get the next 4 TJ's in from the City contract PLUS the first 1 or 2 Retail customers TJs underway to get the first RC Kit (Release Candidate) into testing late June, early Aug for a Sept small batch open sale (maybe just 10...) to be delivered to advanced* retail customers and builders by Jan of 2027.
That's the plan.
We'll put aside the CJ and YJ Kit work for now, get one compete Kit for TJs out and see what the world looks like.
- Patrick
*
Advanced Retail Customer qualifications:
- TJ in the right shape, mostly stock
- Owns a cherry picker or his neighbor does
- A friendly neighbor that can help.
- De-ICE'd TJ, ready to be electrified.
Neah, that's stupid, don't say things like that, it's not a good look.
BUT, if you insist, and to prove your point, I've got a box of distributor contact points I'll let go of VERY cheaply. You come fetch them, they'll be outside in a box next to the freedom-restriction seatbelts and you can get rid of all that fuel injection electronic crap and go back to points.
Ugh, you're only saying that because you don't understand it. Electric Parking Brakes are an IMPROVEMENT, not crap.
Just to push you over the 'electronic crap' edge, we also use the Volvo P/S unit (flawless) and the Bosch iBooster (equally flawless) for P/B and, as listed above, the Guchen A/C compressor. Just those three parts alone, save about 19-24% of the waste HP of an ICE (Internal Combustion Engine) setup.
No, it's not crap, you just aren't familiar with it yet. I get that, I do.
I assume you've used the Wilwood EPB, so you speak from experience, yes?
- Patrick
The plan, (I laugh as I type that word...), the plan is to get this first TJ done with a donner TJ to keep as the proof/demo TJ and get the next 4 TJ's in from the City contract PLUS the first 1 or 2 Retail customers TJs underway to get the first RC Kit (Release Candidate) into testing late June, early Aug for a Sept small batch open sale (maybe just 10...) to be delivered to advanced* retail customers and builders by Jan of 2027.
That's the plan.
We'll put aside the CJ and YJ Kit work for now, get one compete Kit for TJs out and see what the world looks like.
- Patrick
*
Advanced Retail Customer qualifications:
- TJ in the right shape, mostly stock
- Owns a cherry picker or his neighbor does
- A friendly neighbor that can help.
- De-ICE'd TJ, ready to be electrified.
Neah, that's stupid, don't say things like that, it's not a good look.
BUT, if you insist, and to prove your point, I've got a box of distributor contact points I'll let go of VERY cheaply. You come fetch them, they'll be outside in a box next to the freedom-restriction seatbelts and you can get rid of all that fuel injection electronic crap and go back to points.
Ugh, you're only saying that because you don't understand it. Electric Parking Brakes are an IMPROVEMENT, not crap.
Just to push you over the 'electronic crap' edge, we also use the Volvo P/S unit (flawless) and the Bosch iBooster (equally flawless) for P/B and, as listed above, the Guchen A/C compressor. Just those three parts alone, save about 19-24% of the waste HP of an ICE (Internal Combustion Engine) setup.
No, it's not crap, you just aren't familiar with it yet. I get that, I do.
I assume you've used the Wilwood EPB, so you speak from experience, yes?
- Patrick
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