Kdaporcupine Posted April 18, 2022 at 10:57 AM Report Share Posted April 18, 2022 at 10:57 AM So, to anyones knowledge. Is there a place where you can basically convert the energi to a full ev or even just install a bigger battery? i know i know itd be a lot of money etc etc. buy a mach e or tesla. BUT i love my energi platinum. And as much as i want a mach e 40k is still a lot. Ive been looking for replacement energi batteries. But couldnt just a mache battery pack work just as well? I dont need the power but i guess technically cant one just take out all the ice components leave the charging connector and just put in a mache motor with some big batteries from maybe a tesla or something? Completely oversimplified yea, and I probably wont do it and if i do id need a second car but just wondering if anyone else has thought or done a full conversion Quote Link to comment Share on other sites More sharing options...
muzicman61 Posted April 19, 2022 at 03:16 PM Report Share Posted April 19, 2022 at 03:16 PM Nice idea but I doubt it's possible. Of course, they say anything is possible but is it logistically feasible? Quote Link to comment Share on other sites More sharing options...
Ffe Posted April 19, 2022 at 11:09 PM Report Share Posted April 19, 2022 at 11:09 PM Where you gonna put it? roof rack? say goodbye to the whole trunk? I'd certainly read about it if you gave it a try. Lord knows I'm a whore for more range. Quote Link to comment Share on other sites More sharing options...
jsamp Posted April 20, 2022 at 06:01 AM Report Share Posted April 20, 2022 at 06:01 AM You'd either lose the entire trunk to batteries (and mess up the weight distribution), or you'd have to split up the battery to part in the trunk and part under the hood. A far less than ideal setup. Quote Link to comment Share on other sites More sharing options...
Ffe Posted April 20, 2022 at 07:19 AM Report Share Posted April 20, 2022 at 07:19 AM I didn't know there was space under the hood. I was working on a wooden roof rack myself, using a hacked IKEA PAX shelf. Quote Link to comment Share on other sites More sharing options...
jsamp Posted April 21, 2022 at 03:33 AM Report Share Posted April 21, 2022 at 03:33 AM On 4/20/2022 at 12:19 AM, Ffe said: I didn't know there was space under the hood. I was working on a wooden roof rack myself, using a hacked IKEA PAX shelf. There isn't space. I was assuming he was going full EV and would recoup the space that was created by removing the ICE. Quote Link to comment Share on other sites More sharing options...
Kdaporcupine Posted May 1, 2022 at 09:36 AM Author Report Share Posted May 1, 2022 at 09:36 AM On 4/20/2022 at 12:19 AM, Ffe said: I didn't know there was space under the hood. I was working on a wooden roof rack myself, using a hacked IKEA PAX shelf. I’d actually like to see that. I work at Ikea so anything related interests me lol Quote Link to comment Share on other sites More sharing options...
Kdaporcupine Posted May 1, 2022 at 10:07 AM Author Report Share Posted May 1, 2022 at 10:07 AM On 4/19/2022 at 11:01 PM, jsamp said: You'd either lose the entire trunk to batteries (and mess up the weight distribution), or you'd have to split up the battery to part in the trunk and part under the hood. A far less than ideal setup. From what I’ve researched i could probably get away with a 45Kwh battery using lifepo4 batteries so the current EV battery in our cars use 84 3.2v 25ah batteries for a total voltage of 300v. Now from my understanding, recent batteries have gotten smaller and higher capacity so if I were to take this project on I would get 84 3.2v 150ah batteries (which is where I got the 45Kwh from) If I split the rows into 4 or 5 I’d be able to keep the a similar trunk space (of course through assumptions of basic measurements with WxHxL of a single cell and measuring the size of the battery in the trunk.) I looked up the dimensions of the battery cells I want to use and they’re 7.9” H 8.2” L 1.32” W xxxx xxxx so instead of two rows horizontally I’d do 4 or 5 rows vertically and I’ve considered the weight so I’d probably have to get stiffer suspension Other things I’ve considered: upgrading the charge input, but I concluded that without installing a water cooling system for the batteries it won’t be possible because the heat output would be too much for the air cooled system and also the orange connectors are a different style so without wiring diagrams I wouldn’t be able to properly change the plugs reason that i wanted to do it: the charging rate is at 14a or 3.3kw. So I wanted at least a 30a charger but the only one I found was a 6.6kw which would decrease charge time by half. Especially if I do upgrade the battery but anything higher than a 3.3kw charger requires a water cooling system i wouldn’t be able to confirm anything until I actually remove the battery cover and inspect how the batteries are packed. And if I’d be able to remove all the wiring and maybe make a custom enclosure. my reasoning to why it could be done: As long as I stay at 300v of what our batteries are rated at and just increase capacity then it should work. Other people have taken parts from EVs and thrown whatever battery they can find and make it work. The computer on board is smart enough to know when the capacity of the battery is lower because it tells us our range left after years of degradation. so I’m assuming that the computer is also smart enough to know when the range is higher but the voltage is the same so not frying anything on the inside Like I said before it’s a hypothetical and I wouldn’t take the project on for maybe another year for when my HVB battery is closer to maybe 1.5kwh since it’ll just be like having a basic hybrid. And since ford won’t do anything to help I see no point in paying nearly 8k to replace a battery with 1/25th of a Tesla battery when they’re about 20k for 75kwh oh and that’s also another thing ive messaged a seller on alibaba and for 84 cells I’m looking to spend about 3k on the batteries with shipping included below I’ll put the links that I’ve used to calculate stuff and where I found the amount of batteries we have in our energis https://www.greencarreports.com/news/1115817_2019-ford-fusion-energi-plug-in-hybrid-gets-25-miles-from-revised-battery “The new battery continues to hold 84 individual lithium-ion cells, though it weighs 3 percent more than the previous version.“ battery size calculator https://www.inchcalculator.com/ah-to-kwh-calculator/ type 150 for the amps 300 for the v and youll get the 45Kwh the manual to remove the HVB In a safe manner https://elvsolutions.org/wp-content/uploads/2016/02/2017-Fusion-MKZ-HEV-Battery-Removal-Guide-Final.pdf Dimensions for the battery cells https://www.lifepo4-battery.com/Products/CATL-Battery/CATL-CB260-150ah.html charge rate calculator https://www.homechargingstations.com/ev-charging-time-calculator/ I’ve had fun looking all this up so I do think it’s feasible. I have the tools to do it. I would just need the time and money haha. jj2me 1 Quote Link to comment Share on other sites More sharing options...
Ffe Posted May 1, 2022 at 03:01 PM Report Share Posted May 1, 2022 at 03:01 PM This would be epic! I will absolutely follow in your footsteps if you pull this off! 6x the electric range? Count me in! Heck maybe I'd just double or triple it to save money and weight/space and still be happy with that. Quote Link to comment Share on other sites More sharing options...
Kdaporcupine Posted May 2, 2022 at 08:56 PM Author Report Share Posted May 2, 2022 at 08:56 PM On 5/1/2022 at 8:01 AM, Ffe said: This would be epic! I will absolutely follow in your footsteps if you pull this off! 6x the electric range? Count me in! Heck maybe I'd just double or triple it to save money and weight/space and still be happy with that. I know it sounds epic. But I’ll get back to this forum in time when I do have the money to go fully into this project. For now I’ll probably order a couple cells and maybe work on a box or method to wire everything up so I’ll keep the forum updated! Quote Link to comment Share on other sites More sharing options...
testriderchuck Posted July 16, 2022 at 03:53 PM Report Share Posted July 16, 2022 at 03:53 PM If you're wanting to convert something, start with an S10 or Ranger, small engine, 4spd tranny. Remove engine, related stuff. Replace weight with batteries etc. I found a book written 20+ years ago about how to do this. Guys were getting 100 miles with lead acid batteries, DC motors. Same weight LiPo you'd probably get 300+, if you had the room. Best wishes. Quote Link to comment Share on other sites More sharing options...
mathygreen Posted August 10, 2022 at 04:26 PM Report Share Posted August 10, 2022 at 04:26 PM Is there a place where you can basically convert the energi to a full ev or even just install a bigger battery? I know i know itd be a lot of money etc etc. buy a mach e or tesla.BUT i love my energi platinum.And as much as i want a mach e 40k is still a lot.I have been looking for replacement energi batteries. But couldnt just a mache battery pack work just as well? I dont need the power but i guess technically cant one just take out all the ice components leave the charging connector and just put in a mache motor with some big batteries from maybe a tesla or something? Reliable Permit Solutions, LLC Quote Link to comment Share on other sites More sharing options...
jsamp Posted August 11, 2022 at 12:32 AM Report Share Posted August 11, 2022 at 12:32 AM "A place" as in a place in the car for the battery, or a place that will do the conversion for you? I assume you are asking the latter. There are a few custom shops or hobbyists around who do that kind of stuff, but it would NOT be cheap. Search "EV conversion" on the web and you'll see a few. Here's a good list: https://www.hybridcenter.org/electric-car-conversion-companies/ The thing is, you would might have to get a whole different electric motor and drive system, because the ECV transmission is what blends the ICE and the electric motor to drive the wheels. Without the ICE the ECVT is technically no longer needed. Quote Link to comment Share on other sites More sharing options...
WinterArray Posted January 22, 2023 at 08:08 PM Report Share Posted January 22, 2023 at 08:08 PM i've been periodically looking this thread since it exist.. and i would like to throw an idea out of nowhere . as a 2018 energi owner i'd pay money on a gofundme for it to happen lmao Get funded make it happen ! Business model Title : GoFurther : DIY Hybrid EV conversion Idea: Create a Kit that most plastic part are 3D printable *can help with that just need technical drawing* thinking to send Spools of carbon fiber abs and hotend kit for printers or just hire a printer service to print them and ship. there multiple ways soo its doable Source every other component like cells harnes ect and express-post them ? then boom next thing you know people are asking for other vehicles conversion. since we would allready have all the Stl files for a fusion its pretty easy to change for any other sedan. idk ... anyway Quote Link to comment Share on other sites More sharing options...
regisphilbin Posted February 23, 2023 at 10:08 PM Report Share Posted February 23, 2023 at 10:08 PM @WinterArray, Great idea! Quote Link to comment Share on other sites More sharing options...
Jondc Posted April 29, 2023 at 08:59 PM Report Share Posted April 29, 2023 at 08:59 PM On 5/1/2022 at 6:07 AM, Kdaporcupine said: From what I’ve researched i could probably get away with a 45Kwh battery using lifepo4 batteries so the current EV battery in our cars use 84 3.2v 25ah batteries for a total voltage of 300v. Now from my understanding, recent batteries have gotten smaller and higher capacity so if I were to take this project on I would get 84 3.2v 150ah batteries (which is where I got the 45Kwh from) If I split the rows into 4 or 5 I’d be able to keep the a similar trunk space (of course through assumptions of basic measurements with WxHxL of a single cell and measuring the size of the battery in the trunk.) I looked up the dimensions of the battery cells I want to use and they’re 7.9” H 8.2” L 1.32” W xxxx xxxx so instead of two rows horizontally I’d do 4 or 5 rows vertically and I’ve considered the weight so I’d probably have to get stiffer suspension Other things I’ve considered: upgrading the charge input, but I concluded that without installing a water cooling system for the batteries it won’t be possible because the heat output would be too much for the air cooled system and also the orange connectors are a different style so without wiring diagrams I wouldn’t be able to properly change the plugs reason that i wanted to do it: the charging rate is at 14a or 3.3kw. So I wanted at least a 30a charger but the only one I found was a 6.6kw which would decrease charge time by half. Especially if I do upgrade the battery but anything higher than a 3.3kw charger requires a water cooling system i wouldn’t be able to confirm anything until I actually remove the battery cover and inspect how the batteries are packed. And if I’d be able to remove all the wiring and maybe make a custom enclosure. my reasoning to why it could be done: As long as I stay at 300v of what our batteries are rated at and just increase capacity then it should work. Other people have taken parts from EVs and thrown whatever battery they can find and make it work. The computer on board is smart enough to know when the capacity of the battery is lower because it tells us our range left after years of degradation. so I’m assuming that the computer is also smart enough to know when the range is higher but the voltage is the same so not frying anything on the inside Like I said before it’s a hypothetical and I wouldn’t take the project on for maybe another year for when my HVB battery is closer to maybe 1.5kwh since it’ll just be like having a basic hybrid. And since ford won’t do anything to help I see no point in paying nearly 8k to replace a battery with 1/25th of a Tesla battery when they’re about 20k for 75kwh oh and that’s also another thing ive messaged a seller on alibaba and for 84 cells I’m looking to spend about 3k on the batteries with shipping included below I’ll put the links that I’ve used to calculate stuff and where I found the amount of batteries we have in our energis https://www.greencarreports.com/news/1115817_2019-ford-fusion-energi-plug-in-hybrid-gets-25-miles-from-revised-battery “The new battery continues to hold 84 individual lithium-ion cells, though it weighs 3 percent more than the previous version.“ battery size calculator https://www.inchcalculator.com/ah-to-kwh-calculator/ type 150 for the amps 300 for the v and youll get the 45Kwh the manual to remove the HVB In a safe manner https://elvsolutions.org/wp-content/uploads/2016/02/2017-Fusion-MKZ-HEV-Battery-Removal-Guide-Final.pdf Dimensions for the battery cells https://www.lifepo4-battery.com/Products/CATL-Battery/CATL-CB260-150ah.html charge rate calculator https://www.homechargingstations.com/ev-charging-time-calculator/ I’ve had fun looking all this up so I do think it’s feasible. I have the tools to do it. I would just need the time and money haha. @Kdaporcupine, any update on this project? I’m in the same boat and would love to do this myself if your concept worked out Quote Link to comment Share on other sites More sharing options...
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