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Discussion Starter · #1 ·
Hey there! New to the club, but not to the forum. You guys helped me change my timing belt and install a stereo into my '02 xterra (4wd, auto, VG33ER), and gave me some good laughs reading about the horror stories of changing spark plugs. Btw, it's not that bad ?. Wait until you have to remove a portion of your supercharger, and fuel injection system to get to #4 ...that one is tricky.
My topic today is about installing a DC motor into my xterra in place of its V6. I love my little truck, its the perfect size for everything and sits high enough in the air to not blind you with headlights in the rear view, and its just so rugged and solid. My particular xterra has 160,000 on the Odo and I found out what a timing belt failure was the hard way. I've since replaced it (thank you on the awesome write ups).
But, I'm willing to bet on single handedly funding the middle east oil economy with its downright atrocious gas mileage. The supercharged models require premium, *especially* after yours truly installed an aftermarket pulley on it's eaton m62. I despise it's 14mpg average. Maybe that's just my X but it's hard to justify when I traded a 2000 mountaineer (5.0 V8) that gave back 22mpg at 55mph.
I've been looking into DC motors for a long time for their simplicity and economy, I've compared the pro's and con's on using DC over AC, and I've used the calculators (provided on most EV forums) to find out how much motor I need. Fabricating a backing plate isn't a concern for me- my big hang up is the transmission. 5 hours of a Google search gave me the name of my X's auto (Jatco) but no searching yielded me the answer as to whether or not it shares the engines ecm or if its a standalone. I'd love to keep the transmission and driveline intact. If keeping my auto/Tcase is out of the question i'll hang a pair of DC motors under the truck, and mount one to each drive axle (front and rear).
My question to you incredibly educated gentlemen, is have you ever heard of an electric conversion being done to an xterra? Or am I charting new waters here?
(Btw-I'm looking at 240V, forced air cooling, and a small generator underhood to extend range when there is no where to charge up). Thank you for all the help you've given me already, it's much appreciated.
 

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The tranny does communicate with the main ECU. Withe X there have been very few engine swaps, there was a nissan mechanic in tx that even tried swapping a factory diesel from a south american X and had issues. So unless you really know what your doing this will be a pipe dream. And ii'm not some EV hater either. This is my collection of nissans.
 

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I'm still doing research, shopping for a good reliable motor(s) for the conversion. I was hoping the engine and transmission didn't share an ECM. It can't ever be easy, can it ? Lol. Not being able to use the transmission isnt as big a hassle for installation, I was just hoping I could utilize its OD and gears to help accelerate. At 50kw x2 there's enough motor to move an X along at 55, but I doubt I could get batteries with enough capacity to run down the highway for an hour or so. One of my other ideas was to separate the transfer case from the transmission and run the DC motors output shaft to the input of the T-case (utilizing a coupler and shaft). Does the transmission separate like say..a general motors driveline? Or a Ford?
 

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Discussion Starter · #4 ·
EV motor conversion update:

I sourced a 25kw (@72v) BLDC (Brushless DC) motor from a commercial vehicle supplier in China. They'll take brief hits of overcharge, say...to 96v or so, to help get a vehicle rolling. Using their controller it's possible to generate a maximum of 590 lb/ft at the shaft. The price? $1,500 w/controller. I've also sourced a bunch of Li-ion 12v and 24v batteries to build a bank behind the seat. Once I've got all the parts figured out I'll post the total cost, and the links to find them.
 

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Interesting project. I wish you luck with it.well outside my skills but interesting. One bit of inspiration, look up Neil Young's electric Mercury . It was a 64 Mercury converted to full electric. Not sure if it's still going or not.
 

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Discussion Starter · #7 ·
I'm aiming to go at least to work and back. I can plug a charger in at my shop and recharge the batteries at the very least. That would be about 35-40 miles one way with no highway driving and some rolling hills (not great big ones, but enough for my X to have drop out of overdrive to climb). I drive at 55 normally, so that's really all I'd need. 75 would be great for the times I do take trips into grand rapids but in all reality my driving just takes me into town to get pellets for the stove and sometimes a burger. Since I've been researching for this the VG33ER in my truck has started to rattle really bad and I'm not going to put the money down to replace it with another ICE that gets atrocious mileage, for an exorbitant price. Jasper wants something around $4,500 for a brand new motor. No thank you. Thats more than I paid for the vehicle. During the last week I ended up staring at this air compressor motor at my shop, its a large 440v 3 phase industrial AC motor. The casing is easily 13" across, and almost 2' long. An eBay search yielded its clone for a meager $170. My thoughts were that, at 500 amps that motor would make more horsepower and far more torque than my v6. Could likely get away with 250-300 amps and save some money for the controller (netgain has a 360v, 1400 amp beast that can feed 700hp...for $4,500). I'm still in my research phase, and learning about how a home built EV gets put together. My goals are 1) Make my daily commute on a charge. 2) Do the speed limit at the very least. 3) Use an auto & T-case (likely a Chevrolet or ford driveline) 4) Document the build so that it can be replicated for the next guy.
 

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Have also been interested in starting a conversion on our 2000 X. The battery requirements do not seem realistic even if using refurbished tesla modules.

vehicle weight: 3700
energy requirement: 370 wh/mile

desired range: 120 miles
usable wh: 80% = 44.4 kwh
required wh: 100% = 55.5kwh
55.5kwh / 100 ah = 555 volts required
3.3 volt / cell = 169 cells

If anyone has more information on a better approach to this please let me know.
 

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Have also been interested in starting a conversion on our 2000 X. The battery requirements do not seem realistic even if using refurbished tesla modules.

Yes, hard to justify the cost even with used cells. The Leaf cells are much more stable and safe for a conversion. I have had two customers burn up their cars (and one house) by using the Tesla cells.
I see more guys swapping in the TDI diesel for better mileage and power.
http://gastodiesel.tdconversions.com/
 

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Thank you for the diesel recommendation and forewarning regarding the Tesla cells! I do want to convert to electric regardless of what vehicle body is used. I haven't ruled out the Xterra just yet.

The Nissan Leaf battery modules make the most sense at this point. If I can find a local salvage then it'll be worth it.
 
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