[WIP] Jimny using Phev parts

[FFMan]

So after my first EV project met an untimely demise, my son and I are embarking on my second conversion.

This project has been approved as his main engineering project at Silverstone UTC, and I was keen to do another, as a short range EV definitely has a use in our household. So much so we're currently running a Zoe for school runs etc. That is a cracking town car BTW, especially if you get the newer one with more range - but I digress.

I wanted something a bit quirky and simple, with room for batteries and/or electronics underneath, so the Jimny idea was settled on.

I procured for £1300 a rare version i..e not terminally full of rot , with a grumbling gearbox. It's a 2005 facelift which means round airvents, and electrically switched transfer box rather than levers. Ladder chassis, live front and rear axle - its not sophisticated but it has a certain charm for round town use.

Mechanically and electrically very simple, no CAN bus, no trickery and all supported by fantastic Suzuki documentation.

Some maths dictated that we need to keep the transfer box in Low range for its 2:1 gearing, but I've removed the front prop as we don't need 4wd, and there is no centre diff, so 4WD is strictly on loose stuff only. I have a concern the transfer box may prove a bit noisy in Low at speed but we'll see.

The conversion will follow my previous route, PHEV motor, inverter & charger. Homebuilt VCU and charge controller. 2 x 12kwh packs of BMW 330e batteries. Most of these bits I have from the previous conversion so outlay is minimal. Electric motor sits approx where gearbox was, will drive the transfer box via a prop, all of which leaves lots of engine bay for batteries.

One thing I will consider doing differently is cabin heating. Before I used the phev water heater with a pump. It worked but was never great. I know some people have used HV heater elements embedded in the internal heater box/matrix, and it seems to me, this would provide quicker and more hot air. Any feedback on use of these elements appreciated.

I'll pop some pictures in here from time to time. We're half way through making the motor mounts at present which is where we started having removed all the non-required parts from the Jimny.

[Bigpie]

Welcome back. Nice project

[FFMan]

Welcome back. Nice project

thanks - been plotting this for a while - got to be done by May for the school

[FFMan]

Just a quick update - some posts can be found on my sons LinkedIn page https://www.linkedin.com/in/chris-meek-engineer/

The major mechanicals are done, motor is in, prop is back from build & balance and the inverter and charger are mounted under the car where the fuel tank was. 24KWH of batteries are mounted where the engine was. Power steering & vacuum pump all installed and working.

So we're in the wiring phase, and then code, most of which i have from my previous build. Only major mod is use of s-box rather than my own contactors.

Still hoping to have it moving under its own power for May 6th to present at my sons open day at Silverstone. The school have said he's done enough to get the project signed off, but naturally we want it working if we can.