Electric Ranger Conversion Project

The project, to take a standard Ford ranger and convert to electric vehicle for local use due to the high costs of fuel.
Having already built a electric bicycle and electric ATV, I thought it is time for this project.
I have chosen a 144 volt system with a Netgain Warp-9 motor, Curtis 1231c controller.

Sunday, August 24, 2008

Motor gets installed


After modification of the mounting plate and mounting to the motor the adapter was tightened and the motor was ready to install. First thing that had to be done was cut down the transmission shaft with a die grinder and drill and tap some new mounting holes in the transmission due to the difference in the mounting plate.
The motor was hoisted into the engine bay and bolted up without any real issues. I connected the battery to the motor and spun it with the transmission in neutral to check for vibration.
After some measurements, I fabricated the pieces that make up the motor mounts. I drilled the frame rails and installed the mount that supports and clamps the motor in place. I made a torque rod from some scrap round stock to ensure the motor would not rotate in the other mount, I bolted it from the transmission adapter plate to the frame.
I hooked the motor to the existing battery and tested the mounts, the first vehicle movement under electric power.

Sunday, August 17, 2008

Mounting plate continued


The aluminum plate finally arrived after a shipping mix up. I cut and drilled it and the mounting plate for the motor. I found that I will need to shorted the transmission shaft or space the motor off the mounting plate 1/2 inch. I decided to cut the shaft being easier and faster.
I also had to drill out the locating dowels for the plate so the bolts will pass through them.
All that is needed is some new bolts and drill the frame for the middle motor mount.

Sunday, August 10, 2008

Mounting Plate

I started the day cleaning the engine bay and transmission with degreaser and pressure washer.


The mounting plate that was ordered off Ebay was for a later year truck so it didn't line up with the mounting holes. I have decided to use this plate as the locating dowels and transmission shaft line up with the motor bolt pattern.


I ordered a 1/2 inch thick piece of 6061 aluminum on line and cut it to size to clamp the mounting plate to the transmission. I also made a new cover plate for the transmission to cover the starter hole.


Drilling the holes is all that is left to complete the mounting plate setup, then it will get bolted to the motor and test fitted.