Big thanks to Ridge for supporting the channel, and making the wallet i've personally been using for the past 3 years. Here’s the site if you want to check them out! --> ridge.com/jerryrig
I'm gonna be honest... I find humV and garden videos more interesting than the actual main content of the channel. I could literally watch you guys take care of your garden and building cars, jerry rigging stuff all the time.
I think Zack made an excellent pivot with this series. Most likely was losing viewers with the phone videos already. The same old "little legos", "scratches at a level 7" quips get old after a while. I know I wasn't watching any of the disassemblies or durability tests anymore - but this content is excellent, I could watch for days!
As many have already pointed out, be mindful of isolating dissimilar metals. Steel and aluminium will get you really bad corrosion (on the aluminium) and failure of critical parts is never nice. I just replaced shock mounts made of aluminium with painted carbon steel for that reason. Got weird remarks from auto parts store regarding rusting, showed him pics of corroded aluminium mounts surrounded by pristine steel. Also, please reinforce the driveshaft tunnel: aluminium in most grades is like butter for sharp/ballistic/high velocity impacts.
If you have that much corrosion, it sounds like you may want to add some anodes to your frame. Exactly same principle, but it is on the helpful side :)
@@Krieghandt I'm not aware of an effective way to add sacrificial anodes to a car unibody and subframes. Ironically, the aluminium shock mounts that are factory installed on many models kind of act as a sacrificial anode... but it kinda sacrifices your safety when they get corroded and fail suddenly.
This is going to be a one-of-a-kind build totally unique to Jery. The continual updates show just how much technological research has been put into this build.
Zack talks about an EV as well as filling, stretching and drilling holes, while simultaneously talking about how a small piece of rubber is always good to have. Love it
Zach is the first UA-camr to bring up the high price of Ridge Wallet while actually showing that he has and still does use their product. That makes him more trustworthy on this sponsorship than any other channel I've seen sponsored by them.
All the other generic ads have ruined it for me, I will never support Ridge Wallet. Thing looks way too bulky anyway, it can't compete with my Slimfold Micro.
Haven't seen anyone else mention it yet, but you really need to be wearing a respirator when cutting the original sheet metal of the humvee. Military spec ones used a chemical resistant paint that is really harsh on your lungs when airborne (from cutting, sanding, probably even just drilling, etc)
15:55 I noticed a distinct lack of clutch sounds! When you have to screw a bunch of fasteners in and they're all practically identical situations (thread, thread engagement, material, etc,) you can set the torque controlled clutch on your drill using the numbers on the ring so you can just zip 'em in and the clutch will slip when the torque gets too high. Really handy for assembling furniture & EVs & whatnot.
This man is really talented. Sometimes he’s a doctor, a teacher, a coach. You mostly know him as a smartphone surgeon, and now he turns out to be a super genius mechanic. Impressive!
Maybe a suggestion: you could do away with one less module. That way your max battery pack voltage < traction inverter max DC voltage This would protect the Inverter especially when a situation comes where you are either overspeeding with no load (think downhill) i.e. back EMF buildup or Regen at top of the charge, you won't damage the inverter by overvolting it. Also you would save weight (which gives you some range back). Also would be fine, range, voltage (427.8Vdc max) and performance wise if you go 90% SoC with just 17 modules. In your current method, you'd be just carrying dead weight and unusable 5.6kWh if you are not going to charge to the top all the time with possible damaging opportunities to the inverter/motor. Another thing to keep in mind, with the modules mounted vertically, you would have coolant looping vertically. Make sure your coolant reservoir is placed at the highest point relative to the battery coolant lines to ensure bubbles (if any) can find a way to escape. With vertical layout, last thing you want are bubbles getting stuck at some corner at the bottom and with any pump failure or mismanagement, you don't want hotspot/latent heat buildup due to stuck air-bubbles. Would suggest vaccum fill your coolant to minimize air in the lines and coolant path inside the modules.
5:52 Can we stop for a second and appreciate that Jerry is aware of the fact that there are people who use the metric system and that he calculates everything for us? Thanks! :D
I find it so cool that Zach keeps reminding us (and himself) that he still hasn't cleaned up the cables :) I can sense there will be one full episode dedicated to cabling ahah. Thank you so much for these videos. Awesome!
Interesting build. I'd recommend using a drive shaft loop of some sort to hold it in case of it breaking (steel not aluminum) under the power packs above it.
7:23 I'm currently restoring a couple of Ford Ranger Electics, and I couldn't agree more. There's just not enough DIY EV "how to" information out there. At least not in a way that actually demonstrates the work that's being done. Thanks for doing this!
TBH, I think is for a reason... except for Richie Rebuilds, all the other companies just want to keep their know-how, IP and charge 100,000 to convert a Beetle
It seems like a lot of people are on EV DIY forums and there is next to no technical knowledge openly being discussed as well. If there is discussion, it's two guys discouraging the OP, and two other guys having an unrelated pissing contest with eachother, in the OPs thread.
A easy solution for the parking break would be a electric parking break conversion which is available from multiple manufacturers. With a ev a electric parking brake is actually a better choice anyways. All you need for a electric parking brake is a linear actuator with the correct force and travel. I have made them many times and I simply cnc plasma cut a bracket out.
The fact that people have this much dedication is insane to me... even the research alone that goes into something like this is ridiculous; let alone actually doing it. Keep it up, im excited for what the future has in store for this bad-boy
no is very ez if u know fundamentals another guy on youtube re built tons of teslas himself this not new but just remember these cars will not help the environment
I swear whenver a new H1 video is up, I clear the room for (in this case) 26mins of pure automobiel greatness. Thank you you so much Jerry for this. Its just what us dads need in lockdown. Cant wait to see the end results but at the same time dont want the series to end :D
Hey, you really need to add at least one driveshaft hoop on the center battery box, just so that in case of driveshaft failure, you don't end up with a punctured battery. One hoop at either end of the box would probably be the best
An important WARNING for anyone that wants to work with these battery modules: remove any metal from yourself. No bracelets, rings, pendants etc. for obvious reasons you don't want anything to accidentally make contact with live parts of the battery.
And don't put much pressure on the plastic cover covering all the fuses. I cringed when he put the sharp corner of one module onto the cover of another module.
This thing is cool. Do worry about condensation in battery housings and also if there is enough space for normal battery expansion. Although I expect you already solved both those issues. So easy for me to watch and find small issues but no way could I do this. Well done and can’t wait to see it working.
Can't wait to see how you'll install the final assembly! Those conduits look permanent enough that you might have to install all 3 battery boxes at once with a lift. (Also the conduits should be orange colored to indicate HV connections IMO)
@@bashaaksema94 well, I think it's useful to know what _not_ to cut in an emergency situation, and orange cables basically mean "cutting this will result in a very bad day" and I would want to extend that warning to any conduit that carries those kinds of cables.
The internet needs this level of quality when it comes to conversion vlogs. I'm a little sad to see it turn into a two-seater, but happy that you're making progress so fast. I was curious how you were going to handle the batteries. I assumed they would all get stuffed into that massive tunnel and engine area, it would have been a nightmare, but it's not like I have to do it haha.
@18:27. Yeah, That's an original .50 Caliber link. 40 years ago I operate the 'MA DEUCE' in the middle east when I was in the military. The shooting was much quicker than making the ammo belts ;-) In the near future, I want to convert a double-decker bus to ev. So interesting to see your approach with the Tesla batteries. Great job Jerry ;-)
@@MD-vk3bj Thanks, I will make video's about the conversion. But first I am going to convert a double-decker to RV and then to electric. I am going to record that to.. I know that is done before.. But there is a little difference with my conversion. I am disabled so it is going to be a challange. ;-) I have my licence back for driving heavy trucks. Now I am working on the background to make it possible. Will take a while. But coming soon !
i highly recommend using spiral flute taps for blind holes. standard taps 'push' the chips deeper into the hole but spiral ones pulls them out which makes the job 300% easier
Hey man. I have been watching your humvee videos for a while now and watch them every time they pop up. I love it. I just wanted to make a recommendation though. I would put some rubber insulation between the frame and your boxes. It will help separate any electrical issues but also you won't have metal on metal so it will help with sound isolation and prevent future wear. Hope this helps.
Amazing work Zack! I appreciate all the efforts to be safe with the high voltage (I've done a lot of work with high voltage DC as well). I did wonder if you were planning on adding a rubber lining or some additional insulation in the battery boxes? I saw you had stand offs to create separation on the bottom, but seeing a conductive metal sheet so close to the positive and negative terminals makes me anxious! Incredible project! I hope to do work like this in the future and put my engineering degree to work!
The sad thing is either his will be just before or at the same time ... , happy news is that the cybertruck top model is announced to be 4 motors and back wheel steering , and will come out first , we do not know about the other versions yet, but i hope they will just add 1 motor for pre-orders, 1 to 2 , 2 to 3 , 3 to 4 , and have the back wheel steering on 3 and 4 motors.
Jerry my man, loving the content on the Hummer. I would recommend some anti-seize lubricant on the steel screws in the aluminum battery boxes. You're gonna want to prevent any corrosion on those different metals from starting.
@@ahfreebird Exactly what I was thinking, better that he's not in the rust belt like myself lol. One Chicago winter and good luck replacing a bad battery module
The Liquid-Tite conduit connectors need a screw on plastic bushing after the lock nut to prevent chafing. Excellent job on the build. Love the channel.
The Battery Placement and perfect location at the CG, It's beautiful, all the boxes actually together rather than at multiple locations and skipping all that HV Cabling Business, Beautiful. The Battery Planning is perfect, and after addition Liquid Cooling you are set. Its coming together beautifully 😍
The carbon fiber ridge wallet holds up really well. I bought one when they first started sponsoring UA-cam videos and it still looks brand new. Highly recommended, especially people who carry lots of cards (business owner here). Never had a wallet before this that was comfortable carrying so many cards
Man, I'm so jealous of you that your local traffic laws allow you to even consider such projects. Really enjoy this series. I kinda wish, it never ends...
So am I! the only project I (even remotely) consider is a tractor, going less than 20 km/h (12.4 mph) because they are exempt from vehicle registration laws (in Norway), and could still do the work I intend it to. Wanting to replace an ATV I have on tractor registration with something electric.
That's the benefits they have living in a free country, rather than the trash we have over here. They also have a thing called, Freedom of Speech, that we don't. I feel bad for people in places like Scotland, where they are jailing their people for offending someone on social media. Disgusting.
@@rkan2 in Norway it is pretty difficult to get the reqired documents and approvals to modify an EV or convert to EV. You need documentations to meet all safety standards. Espessially high voltage system is a callange to get approved. The same problems arize if you want to change battery chemistry for a car too. You can not just swap a led-acid-battery or zebra-battery for a modern li-ion-battery when the original batter reach end of life. It is not difficult if you can provide the documentation. But you need assistance from a professional company, sharing the cost over many projects. It is not somthing you can afford to do for a single project.
@@thorbjrnhellehaven5766 Norway could certainly be an outlier as they are not in the EU - but in neighbouring Sweden and Finland this is certainly possible. Better to do it on a car without ESP/ABS and too many additional safety features though. Although recently at least in Finland you might actually be able to use already approved components from a say a dismantled EV and not go through the EMC testing required for any car (ICE or not) after 2002. In theory this should work in very much the same way where you have the documentation for the donor car much like swapping a drivetrain from another ICE vehicle where you swap basically all hardware including exhausts. Therefore you wouldn't need all the paperwork that would the EC/EU laws require for automakers to be able to get a type certificate. Currently in Finland it is even legal to work on your high voltage system without actual proper education except maybe for a small course on electrical safety standards - as the current law doesn't require any specific education to work on your own car or on a even on a customer's car if you are the sole mechanic. For employees there is different (safety) laws which of course mandate sufficient training.
No, Jerry no! You need to keep it 4-door! Don't you have a battery per door cost/ power delivery? 21:46. Unless you extend the truck bed forwards to cover the 2 doors given up. But again load over battery terminals when access is dearly needed? Will have to unload to fix then reload? Keeping most of the military Hummer is sure the ultimate success in a conversion exercise especially when you mentioned the delay of the (4-door) Tesla Cybertruck as the genesis of all this EV conversion. A double-cab is best Jerry. Keep the 2 rear doors but design retractable seats on hinges or something close to access battery terminals when need arises You should reconsider.
I use your vids to pause during the day, while working from home. An excellent way to enjoy a cup of coffee and lunch. Makes you forget all fussing and fighting in the world. Thanks Zack, you are my absolute favorit UA-camr ✌
I love this project. Maybe it has already been considered, but I hope that drive shaft never breaks. If it does, it might puncture your battery packs. I would consider a carbon fiber drive shaft instead. When carbon drive shafts break they splinter instead of smacking around inside the driveshaft tunnel.
A few days ago I noticed a few rivian electric trucks driving on the 15fwy in the high desert of California. Last Saturday I saw a rivian truck broken down on the side of the road about 5 miles north of the Cajon pass and it left on the back of a flatbed.
Jerry, nice job on the battery boxes. You definitely need to add the heating to the batteries if you live in a cold environment. Also if you ever plan to service or open those battery boxes, you should address the galvanic corrosion you will see when using steel screws into aluminum threads. Also, aluminum threads strip very easily with steel screws. If you plan on opening it more than two or three times in the vehicles life, maybe consider using thread inserts. The thread inserts can also be purchased with coatings to resist galvanic corrosion.
@@dennis8019 he could: - buy them - steal them - get them through a sponsorship - shut the smartass Dennis up with his drill - restore worn out batteries - get them out of a Tesla
WARNING!!!!!! if the rear drive shaft comes off and starts swinging around and hits those battery boxes you are in big trouble. You should put something stronger lining the drive shaft hull
That is exactly right. Even if he had some safety steel rings around the drive shaft there are still big spaces between those rings for great damage and punctures to occur. Not to mention those rings would need to attach to the aluminum box so that not too good either. Should have just done dual electric motors and no driveshaft needed.
Great vid, love watching the build. i must say feels like you have a misunderstanding on the 12v side, as lead acids are old tech but in many senses more robust when when it comes to charging and running. where as lipos can get alot more temperamental on charging and running resulting in the complicated bms systems. amp hour on a lead acid car battery is normally based over 20hours discharge where as lipos is over 1. no battery likes to be discharged to 0volts and recharged, normally a lead acid is considered fully discharged at 10.5volts, where as the lifepo4 can be 10v or as low as 8v when the bms could possibly cut the output for safely but for both battery this would dramatically shorten there lives. Cant wait to see the hummer driving :)
HI Jerry, love your vids always, really cool how you dissect your E-Hummer. Observation and just a matter of caution at 11:28 its better to take off any metal items from your hands and fingers, if you would have touched the battery fuse wire then its BOOM 🔥🔥🚀🚀
I have been working at AM General for 21 years and love watching this build. I don't understand why AM General doesn't have an electric drivetrain as an option. I do have a question for you about the front suspension. What do you plan to use for the front springs?
Please make sure to take into account eddy currents when routing cables through metal otherwise with that amount of power you could have some slight melting happening!
Hi Jerry, great work, I think you need to take into consider the cooling system of the inverter and the AC motor, 1.heat exchanger. 2.water pump. 3.Expansion tank. 4.Tubes & valves. Usually use with ethylene glycol adding to water to prevent freezing.
I hope you remembered to insulate all the contact areas between your aluminium and steel components to stop galvanic corrosion (between the battery boxes and the steel frame of the humvee?). There are all kinds of adhesives that you can use for this.
"...I add a little lubricant, which just helps things go in and out easier." "Because things are little more safe with a little peice of rubber." -Zack, 2021.
I couldnt care less about cars, but this series of videos are just perfect, cant wait for next one, the longer this transformation lasts the longer ill be happy, great work and vid as always, and have fun 😁
AMAZING Project. Can't wait until next episode. 7992 tiny batteries hey - doesn't seem very efficient, but then what do I know! The liquid cooling and warming also does not sound very reliable... There definitely needs to be a better battery developed. The size of the three boxes is way too much and take up too much space and heavy. But I get it, there just isn't any other way now. GREAT WORK - and thanks for sharing the knowledge. LEARNED A LOT from watching these videos.
I believe there’s a factory four inch body lift for some models of the hummer. I would have considered installing that lift so that the battery modules could be placed under the entire floor giving room for either twice as many or usable rear seats.
I aspire to be like you Jerry! You know all the true principals of life… Nothing can beat DIY because you can always do it better if you put in the work. I wanted to convert my Honda but I don’t have the means or tools so I’ll just watch your videos until I can do everything myself lol
Don't forget one annoying feature of Li-ion batteries, well when Lead Acid battery discharges it's voltage drops linearly, but Li-ion have a strap drop from 100-90% and then voltage is stable untill there is about 10-15% of charge left after which voltage drops very quickly. So while you can guess the charge of Lead Acid by measuring Voltage that is not really possible with Li-Ion.
Good advice, A little lubricant helps things go in and out easier. We always need to be reminded about that. I'll wager you have that advice on a shirt.
I really enjoyed the video, a lot of good information delivered in an easy to understand manner. Your work is very professional. You made the comment that you talk a lot, well I am glad you do. All your talk was very useful information. I am using the same Tesla battery cells and it was great to see how you made the boxes. I see you mounted the battery cells in thier edge, exactly what I plan to do. Thank you so much from West Australia.
Gun taps are what you’re referring to, but roll form taps work best in soft materials such as aluminum. They “push” the material into the thread form rather than cutting it retaining its grain structure and strengthen the threads.
Very intresting video. You are very good to explaining the whole system. I understood and gave me very good details of the power, circuit board and how things works. Amazing Cheers.
Big thanks to Ridge for supporting the channel, and making the wallet i've personally been using for the past 3 years. Here’s the site if you want to check them out! --> ridge.com/jerryrig
Remeber your "notawheelchair" could you make another video about it please???
I love your project and you helped me decide to buy on not buy a realey expincive phone we love and value your efforts
hello bro love to watch your vedio
Hey man
Shoutout please
I'm gonna be honest... I find humV and garden videos more interesting than the actual main content of the channel. I could literally watch you guys take care of your garden and building cars, jerry rigging stuff all the time.
They're awesome but i think the content balance in the channel is just perfect right now. I find very interesting all of his videos tho
🏳️🌈
Totally agree
I think Zack made an excellent pivot with this series. Most likely was losing viewers with the phone videos already. The same old "little legos", "scratches at a level 7" quips get old after a while. I know I wasn't watching any of the disassemblies or durability tests anymore - but this content is excellent, I could watch for days!
Same for me
"Things are a little more safe with a little bit of rubber"
Cambry holding Cyrus: (◕દ◕)
😔🤣
He made more in this video.
They are super stealthy 😂
Was looking for this comment 😭
😂😂😂
I mean, he's obligated to make dad jokes now.
I was really waiting for this update on the Hummer! This series is my favorite!
electric hummer time
You're cute.
@@trxtech3010
Your mom is cuter.
As many have already pointed out, be mindful of isolating dissimilar metals. Steel and aluminium will get you really bad corrosion (on the aluminium) and failure of critical parts is never nice. I just replaced shock mounts made of aluminium with painted carbon steel for that reason. Got weird remarks from auto parts store regarding rusting, showed him pics of corroded aluminium mounts surrounded by pristine steel. Also, please reinforce the driveshaft tunnel: aluminium in most grades is like butter for sharp/ballistic/high velocity impacts.
If you have that much corrosion, it sounds like you may want to add some anodes to your frame. Exactly same principle, but it is on the helpful side :)
Old conveyor belt makes a good isolator and would also help as a vibration dampener to stop abrasion between mounting surfaces.
@@Krieghandt I'm not aware of an effective way to add sacrificial anodes to a car unibody and subframes. Ironically, the aluminium shock mounts that are factory installed on many models kind of act as a sacrificial anode... but it kinda sacrifices your safety when they get corroded and fail suddenly.
Hello friend how are you ?
Dude I'm taken back by the sheer level of engineering you are doing on this build. I cannot wait to see the finished product.
This is going to be a one-of-a-kind build totally unique to Jery.
The continual updates show just how much technological research has been put into this build.
His name is Zack
Zack talks about an EV as well as filling, stretching and drilling holes, while simultaneously talking about how a small piece of rubber is always good to have. Love it
Also lube.
Stretching haha
Wait his name's not jerry
Zach is the first UA-camr to bring up the high price of Ridge Wallet while actually showing that he has and still does use their product. That makes him more trustworthy on this sponsorship than any other channel I've seen sponsored by them.
I actually bought one for my dad. Its actually really good...
Exactly why I have finally ordered one just now. I've been in need of a new wallet for ages now.
Nailed it perfect. The honesty on this channel is just flawless
All the other generic ads have ruined it for me, I will never support Ridge Wallet. Thing looks way too bulky anyway, it can't compete with my Slimfold Micro.
One of the cards says Jerry... :-)
Haven't seen anyone else mention it yet, but you really need to be wearing a respirator when cutting the original sheet metal of the humvee. Military spec ones used a chemical resistant paint that is really harsh on your lungs when airborne (from cutting, sanding, probably even just drilling, etc)
15:55 I noticed a distinct lack of clutch sounds! When you have to screw a bunch of fasteners in and they're all practically identical situations (thread, thread engagement, material, etc,) you can set the torque controlled clutch on your drill using the numbers on the ring so you can just zip 'em in and the clutch will slip when the torque gets too high. Really handy for assembling furniture & EVs & whatnot.
Super handy for Ikea furniture. So much less stress about potentially stripping cheap threads.
This man is really talented. Sometimes he’s a doctor, a teacher, a coach. You mostly know him as a smartphone surgeon, and now he turns out to be a super genius mechanic. Impressive!
Sir this is Jerry not johnny.
@@ProCarsGaming556 Full of Sins really
@@ProCarsGaming556 sir this actually neither Jerry or Johnny, its Zack
@@GoPotato69 ..... You get the point don't you?
@@ProCarsGaming556 yes yes i do
Be sure to properly ground the chassis of the BMS. As it gets P0A1F(internal cell communication fault) errors while switching high voltage contactors.
Props to whoever did the welding job on the aluminum boxes. Aluminum is very difficult to weld but he did a magnificent job.
Yeah
If only Aloominum were available in the UK. Here, we only have Aluminium to work with :-)
@@TonyLing we only have Aluminum in Australia to. Must be a different compound of metal. 😄
@@noelmoloney8840 You probably mine a shit tonne of it and send it back to the old dart.
Maybe a suggestion: you could do away with one less module. That way your max battery pack voltage < traction inverter max DC voltage
This would protect the Inverter especially when a situation comes where you are either overspeeding with no load (think downhill) i.e. back EMF buildup or Regen at top of the charge, you won't damage the inverter by overvolting it.
Also you would save weight (which gives you some range back). Also would be fine, range, voltage (427.8Vdc max) and performance wise if you go 90% SoC with just 17 modules.
In your current method, you'd be just carrying dead weight and unusable 5.6kWh if you are not going to charge to the top all the time with possible damaging opportunities to the inverter/motor.
Another thing to keep in mind, with the modules mounted vertically, you would have coolant looping vertically. Make sure your coolant reservoir is placed at the highest point relative to the battery coolant lines to ensure bubbles (if any) can find a way to escape. With vertical layout, last thing you want are bubbles getting stuck at some corner at the bottom and with any pump failure or mismanagement, you don't want hotspot/latent heat buildup due to stuck air-bubbles. Would suggest vaccum fill your coolant to minimize air in the lines and coolant path inside the modules.
bro you should reply on jerrys comment so he can notice yor reply
That would have made the parking brake move unnecessary. Oof!
5:52 Can we stop for a second and appreciate that Jerry is aware of the fact that there are people who use the metric system and that he calculates everything for us? Thanks! :D
Hello friend how are you ?
yeah, btw his name is zach not jerry lol
@@AMZG oh damn forgot about that.
23:36 “things are little more safe with a little piece of rubber” - JerryRigEverything 2021
This series is the best! And dad jokes are getting more and more on point!
I find it so cool that Zach keeps reminding us (and himself) that he still hasn't cleaned up the cables :) I can sense there will be one full episode dedicated to cabling ahah. Thank you so much for these videos. Awesome!
we need a Zach building a computer video to test his cable management skills!
Interesting build. I'd recommend using a drive shaft loop of some sort to hold it in case of it breaking (steel not aluminum) under the power packs above it.
Weird friendship...Dan breaks stuff while zack 's handymanship is on another level. Much love from Kenya 🇰🇪
7:23 I'm currently restoring a couple of Ford Ranger Electics, and I couldn't agree more. There's just not enough DIY EV "how to" information out there. At least not in a way that actually demonstrates the work that's being done. Thanks for doing this!
TBH, I think is for a reason... except for Richie Rebuilds, all the other companies just want to keep their know-how, IP and charge 100,000 to convert a Beetle
It seems like a lot of people are on EV DIY forums and there is next to no technical knowledge openly being discussed as well. If there is discussion, it's two guys discouraging the OP, and two other guys having an unrelated pissing contest with eachother, in the OPs thread.
Many battery cells make hummer work. Looking good!
Many brain cells make humans work.
Hello friend how are you ?
A easy solution for the parking break would be a electric parking break conversion which is available from multiple manufacturers. With a ev a electric parking brake is actually a better choice anyways. All you need for a electric parking brake is a linear actuator with the correct force and travel. I have made them many times and I simply cnc plasma cut a bracket out.
The fact that people have this much dedication is insane to me... even the research alone that goes into something like this is ridiculous; let alone actually doing it. Keep it up, im excited for what the future has in store for this bad-boy
no is very ez if u know fundamentals another guy on youtube re built tons of teslas himself this not new but just remember these cars will not help the environment
I swear whenver a new H1 video is up, I clear the room for (in this case) 26mins of pure automobiel greatness. Thank you you so much Jerry for this. Its just what us dads need in lockdown. Cant wait to see the end results but at the same time dont want the series to end :D
Lockdown? Where on earth are you, where they're still doing that? Get out of that dump.
Hey, you really need to add at least one driveshaft hoop on the center battery box, just so that in case of driveshaft failure, you don't end up with a punctured battery. One hoop at either end of the box would probably be the best
An important WARNING for anyone that wants to work with these battery modules: remove any metal from yourself. No bracelets, rings, pendants etc. for obvious reasons you don't want anything to accidentally make contact with live parts of the battery.
And don't put much pressure on the plastic cover covering all the fuses. I cringed when he put the sharp corner of one module onto the cover of another module.
i just can't believe he is working without electric protective gloves
there are a lot of cringe worthy moments in this video.
it's a lot of current, but only 24V
This thing is cool.
Do worry about condensation in battery housings and also if there is enough space for normal battery expansion. Although I expect you already solved both those issues. So easy for me to watch and find small issues but no way could I do this. Well done and can’t wait to see it working.
14:46 oh that TimeSaver is a thing of beauty, so simple but so effective
Can't wait to see how you'll install the final assembly! Those conduits look permanent enough that you might have to install all 3 battery boxes at once with a lift. (Also the conduits should be orange colored to indicate HV connections IMO)
I think only the wires? At least here thats the case
@@bashaaksema94 well, I think it's useful to know what _not_ to cut in an emergency situation, and orange cables basically mean "cutting this will result in a very bad day" and I would want to extend that warning to any conduit that carries those kinds of cables.
@@jtcressy1 true
"Things are a little more safe with a little piece of rubber."
-Zack, 2021.
There's definitely a few double ontouder in the 🎥
@@buckmanriver entendre*
POV: you wanted to write this, but you saw this comment
@@calebvaniperen9599 OMG i do :v
He says this yet he has a child
The internet needs this level of quality when it comes to conversion vlogs. I'm a little sad to see it turn into a two-seater, but happy that you're making progress so fast. I was curious how you were going to handle the batteries. I assumed they would all get stuffed into that massive tunnel and engine area, it would have been a nightmare, but it's not like I have to do it haha.
5:40 _ Uncle Ben: "With great power comes great responsibility"
25:30 ✌️ even I thought the same
Clear glass though surface to see bms and all other connections would be awesome 🥳🥳
@18:27. Yeah, That's an original .50 Caliber link. 40 years ago I operate the 'MA DEUCE' in the middle east when I was in the military. The shooting was much quicker than making the ammo belts ;-)
In the near future, I want to convert a double-decker bus to ev. So interesting to see your approach with the Tesla batteries.
Great job Jerry ;-)
That's awesome! I subbed to you in case you decide to make videos of the conversion. Good luck!
@@MD-vk3bj Thanks, I will make video's about the conversion. But first I am going to convert a double-decker to RV and then to electric. I am going to record that to.. I know that is done before.. But there is a little difference with my conversion. I am disabled so it is going to be a challange. ;-)
I have my licence back for driving heavy trucks. Now I am working on the background to make it possible. Will take a while. But coming soon !
The timing on this couldn’t be better. I started this series yesterday and finished this morning, and then BOOM, another episode. Great work!
i highly recommend using spiral flute taps for blind holes. standard taps 'push' the chips deeper into the hole but spiral ones pulls them out which makes the job 300% easier
Hey man. I have been watching your humvee videos for a while now and watch them every time they pop up. I love it. I just wanted to make a recommendation though. I would put some rubber insulation between the frame and your boxes. It will help separate any electrical issues but also you won't have metal on metal so it will help with sound isolation and prevent future wear. Hope this helps.
1/4" x 1" strips would do it
Hello friend how are you ?
Amazing work Zack! I appreciate all the efforts to be safe with the high voltage (I've done a lot of work with high voltage DC as well). I did wonder if you were planning on adding a rubber lining or some additional insulation in the battery boxes? I saw you had stand offs to create separation on the bottom, but seeing a conductive metal sheet so close to the positive and negative terminals makes me anxious! Incredible project! I hope to do work like this in the future and put my engineering degree to work!
Bro i love this adventure and um glad your taking us along with you
Normal people: I’ll wait for the cyber truck
Jerry: nah I’ll build my own
Love the content and amazing how you also teach about what your doing
The sad thing is either his will be just before or at the same time ... , happy news is that the cybertruck top model is announced to be 4 motors and back wheel steering , and will come out first , we do not know about the other versions yet, but i hope they will just add 1 motor for pre-orders, 1 to 2 , 2 to 3 , 3 to 4 , and have the back wheel steering on 3 and 4 motors.
Nobody: oh look Hummer is coming out with their new Electric pickup, I should buy one of those!
Jerry my man, loving the content on the Hummer. I would recommend some anti-seize lubricant on the steel screws in the aluminum battery boxes. You're gonna want to prevent any corrosion on those different metals from starting.
I’ve been thinking that at almost every turn on this project. In a few years Jerry is going to get a lesson in contact of dissimilar metals.
@@ahfreebird Exactly what I was thinking, better that he's not in the rust belt like myself lol. One Chicago winter and good luck replacing a bad battery module
I have been an Aluminum welder for 10years. Those welds look good! Tig is definitely an art. Stackin dimes!
The Liquid-Tite conduit connectors need a screw on plastic bushing after the lock nut to prevent chafing. Excellent job on the build. Love the channel.
This is absolutely the coolest build on UA-cam. I could listen to Jerry all day about anything!
Keep doing this good Typ of content! Nice Job Zack
"if anything metal touches these uncovered batteries, then... kaboom"
also Zack wearing his metal ring 5 cm away from the battery: 11:27
Haha
That's a rubber ring not metal
The Battery Placement and perfect location at the CG, It's beautiful, all the boxes actually together rather than at multiple locations and skipping all that HV Cabling Business, Beautiful. The Battery Planning is perfect, and after addition Liquid Cooling you are set. Its coming together beautifully 😍
18:38 yes that is the belt clip for the M2 50 cal machine gun that was mounted on the turret of that Hummer.
Deflagration is what occurs inside an internal combustion engine, not an explosion. But I love the project!! Keep it up.
The carbon fiber ridge wallet holds up really well. I bought one when they first started sponsoring UA-cam videos and it still looks brand new. Highly recommended, especially people who carry lots of cards (business owner here). Never had a wallet before this that was comfortable carrying so many cards
Man, I'm so jealous of you that your local traffic laws allow you to even consider such projects. Really enjoy this series. I kinda wish, it never ends...
So am I! the only project I (even remotely) consider is a tractor, going less than 20 km/h (12.4 mph) because they are exempt from vehicle registration laws (in Norway), and could still do the work I intend it to.
Wanting to replace an ATV I have on tractor registration with something electric.
That's the benefits they have living in a free country, rather than the trash we have over here. They also have a thing called, Freedom of Speech, that we don't. I feel bad for people in places like Scotland, where they are jailing their people for offending someone on social media. Disgusting.
Everything he's done should be possible in most western countries actually (North America and at least most EU countries)...
@@rkan2 in Norway it is pretty difficult to get the reqired documents and approvals to modify an EV or convert to EV.
You need documentations to meet all safety standards. Espessially high voltage system is a callange to get approved.
The same problems arize if you want to change battery chemistry for a car too.
You can not just swap a led-acid-battery or zebra-battery for a modern li-ion-battery when the original batter reach end of life.
It is not difficult if you can provide the documentation. But you need assistance from a professional company, sharing the cost over many projects. It is not somthing you can afford to do for a single project.
@@thorbjrnhellehaven5766 Norway could certainly be an outlier as they are not in the EU - but in neighbouring Sweden and Finland this is certainly possible. Better to do it on a car without ESP/ABS and too many additional safety features though. Although recently at least in Finland you might actually be able to use already approved components from a say a dismantled EV and not go through the EMC testing required for any car (ICE or not) after 2002.
In theory this should work in very much the same way where you have the documentation for the donor car much like swapping a drivetrain from another ICE vehicle where you swap basically all hardware including exhausts. Therefore you wouldn't need all the paperwork that would the EC/EU laws require for automakers to be able to get a type certificate.
Currently in Finland it is even legal to work on your high voltage system without actual proper education except maybe for a small course on electrical safety standards - as the current law doesn't require any specific education to work on your own car or on a even on a customer's car if you are the sole mechanic. For employees there is different (safety) laws which of course mandate sufficient training.
No, Jerry no! You need to keep it 4-door! Don't you have a battery per door cost/ power delivery? 21:46. Unless you extend the truck bed forwards to cover the 2 doors given up. But again load over battery terminals when access is dearly needed? Will have to unload to fix then reload? Keeping most of the military Hummer is sure the ultimate success in a conversion exercise especially when you mentioned the delay of the (4-door) Tesla Cybertruck as the genesis of all this EV conversion. A double-cab is best Jerry. Keep the 2 rear doors but design retractable seats on hinges or something close to access battery terminals when need arises You should reconsider.
I use your vids to pause during the day, while working from home. An excellent way to enjoy a cup of coffee and lunch. Makes you forget all fussing and fighting in the world. Thanks Zack, you are my absolute favorit UA-camr ✌
Even though I use Pounds and Fahrenheit
and not kg or Celsius, I appreciate that you go out of your way to put the conversion.
I love this project. Maybe it has already been considered, but I hope that drive shaft never breaks. If it does, it might puncture your battery packs. I would consider a carbon fiber drive shaft instead. When carbon drive shafts break they splinter instead of smacking around inside the driveshaft tunnel.
It'll be just fine.
Came here to say the same thing
23:35 He pulled a sneaky one.
And especially after becoming a father, it's gold.
Lol
LMAO!!! 15:30 too.
A few days ago I noticed a few rivian electric trucks driving on the 15fwy in the high desert of California. Last Saturday I saw a rivian truck broken down on the side of the road about 5 miles north of the Cajon pass and it left on the back of a flatbed.
Jerry, nice job on the battery boxes. You definitely need to add the heating to the batteries if you live in a cold environment. Also if you ever plan to service or open those battery boxes, you should address the galvanic corrosion you will see when using steel screws into aluminum threads. Also, aluminum threads strip very easily with steel screws. If you plan on opening it more than two or three times in the vehicles life, maybe consider using thread inserts. The thread inserts can also be purchased with coatings to resist galvanic corrosion.
This whole series is actually inspiring me to do the same with an older Ford F-150...
How did you get the batteries? Did you buy them?
@@dennis8019 lol, this is EPIC elite shit😂
Daily watering and also vermi compost .
Forget about it Mario
Crashed tesla part's all over the interwebs , you can get everything salvageable from one.
@@dennis8019 he could:
- buy them
- steal them
- get them through a sponsorship
- shut the smartass Dennis up with his drill
- restore worn out batteries
- get them out of a Tesla
WARNING!!!!!!
if the rear drive shaft comes off and starts swinging around and hits those battery boxes you are in big trouble. You should put something stronger lining the drive shaft hull
That is exactly right. Even if he had some safety steel rings around the drive shaft there are still big spaces between those rings for great damage and punctures to occur. Not to mention those rings would need to attach to the aluminum box so that not too good either. Should have just done dual electric motors and no driveshaft needed.
@@RemmikRotus I think with the right bracing the rings would work
Great vid, love watching the build. i must say feels like you have a misunderstanding on the 12v side, as lead acids are old tech but in many senses more robust when when it comes to charging and running. where as lipos can get alot more temperamental on charging and running resulting in the complicated bms systems. amp hour on a lead acid car battery is normally based over 20hours discharge where as lipos is over 1. no battery likes to be discharged to 0volts and recharged, normally a lead acid is considered fully discharged at 10.5volts, where as the lifepo4 can be 10v or as low as 8v when the bms could possibly cut the output for safely but for both battery this would dramatically shorten there lives. Cant wait to see the hummer driving :)
Hello friend how are you ?
5 Star video thanks for taking the time to make this fine video !
You are awesome... The patience you have to convert into an electric vehicle is amazing. It is definitely learning for all of us. Thank you.
HI Jerry, love your vids always, really cool how you dissect your E-Hummer. Observation and just a matter of caution at 11:28 its better to take off any metal items from your hands and fingers, if you would have touched the battery fuse wire then its BOOM 🔥🔥🚀🚀
Hello friend how are you ?
I have been working at AM General for 21 years and love watching this build. I don't understand why AM General doesn't have an electric drivetrain as an option. I do have a question for you about the front suspension. What do you plan to use for the front springs?
Please make sure to take into account eddy currents when routing cables through metal otherwise with that amount of power you could have some slight melting happening!
A definite unintended consequence of going with these metal boxes. As well sealing them against water with all those slits is going to be challenge.
Good point
Unless the motor-driving inverter is complete crap, there won't be much ripple on the DC lines from the battery. No need to worry about Eddy currents.
No eddy currents with DC
Hi Jerry, great work, I think you need to take into consider the cooling system of the inverter and the AC motor,
1.heat exchanger.
2.water pump.
3.Expansion tank.
4.Tubes & valves.
Usually use with ethylene glycol adding to water to prevent freezing.
His name is Zachary
I hope you remembered to insulate all the contact areas between your aluminium and steel components to stop galvanic corrosion (between the battery boxes and the steel frame of the humvee?). There are all kinds of adhesives that you can use for this.
"...I add a little lubricant, which just helps things go in and out easier."
"Because things are little more safe with a little peice of rubber."
-Zack, 2021.
I chuckled at the lubricant comment :)
@@bakariz Same. I need to cleanse my mind. 😂
I couldnt care less about cars, but this series of videos are just perfect, cant wait for next one, the longer this transformation lasts the longer ill be happy, great work and vid as always, and have fun 😁
Holy Jerry hath bless'd us with a Hummer video!
I CANNOT wait for the clean up of the wiring. I just know how meticulously it’ll be done and it’s going to be SO clean I’m excited.
When I watch these videos. I feel like I'm learning something.. military, engineering and even biology! Thanks Jerry / Zack..
Didn't take him that long after becoming a Dad to truly embrace dad jokes. :-)
You will not realise that when those 26 minutes passed away ❤️. Thats the magic of this whole series ❤️
This is so fascinating! Thanks for doing this. I drive a RAM 1500, my next truck will definitely be electric!
AMAZING Project. Can't wait until next episode. 7992 tiny batteries hey - doesn't seem very efficient, but then what do I know! The liquid cooling and warming also does not sound very reliable... There definitely needs to be a better battery developed. The size of the three boxes is way too much and take up too much space and heavy. But I get it, there just isn't any other way now. GREAT WORK - and thanks for sharing the knowledge. LEARNED A LOT from watching these videos.
Can also use kapton tape for electrical isolation, obviously double check the data sheet ,but can be super handy
Had no idea you could use a wood router on aluminium. Cheers mate.
@@N0N0111 There is no such thing.
I think the only reason Zach's finishing this is so he can see the Lazer cutting the metal
Let’s hope Zack will finish this project before the end of this year!!!
That's too optimistic
I think its already finished, he filmed it months ago. Look at some of the earlier videos on this, u can see the snow outside lol
The .50 cal belt link you found is called a "disintegrating link". They are really cool and require special tools/jigs to load.
11:48 The moment that Zack knew he almost screwed up!! Its as easy as that when dealing with large voltages. Stay safe Zack love these videos!!
It's just 4 volt I think so it's safe to touch. Just don't place any metal objects on it because that will cause a short and pop loads of wire fuses.
This is my favorite build I’ve watched to date! Can’t wait to see this thing rip around… keep up the great work! 👌🏻
His voice can both calm and give you a nightmare at the same time...
His cadence and pauses make him sound like William Shatner. lol
I can't wait for the durability test once it's all built
I believe there’s a factory four inch body lift for some models of the hummer.
I would have considered installing that lift so that the battery modules could be placed under the entire floor giving room for either twice as many or usable rear seats.
I aspire to be like you Jerry! You know all the true principals of life… Nothing can beat DIY because you can always do it better if you put in the work. I wanted to convert my Honda but I don’t have the means or tools so I’ll just watch your videos until I can do everything myself lol
Don't forget one annoying feature of Li-ion batteries, well when Lead Acid battery discharges it's voltage drops linearly, but Li-ion have a strap drop from 100-90% and then voltage is stable untill there is about 10-15% of charge left after which voltage drops very quickly. So while you can guess the charge of Lead Acid by measuring Voltage that is not really possible with Li-Ion.
Also true
It is possible with some cleverness. You know the graph and you can map out the state of charge from it. How do you think your phone tells it?
"After being in my pants over a 1000 days, It looks a little hammered" Did you mean to make it sound like this Zack? haha
Well if a hole in the roof is a sunroof, can we call the hole in the floor, “The Moonpool”
moonfloor maybe?
Good advice, A little lubricant helps things go in and out easier.
We always need to be reminded about that.
I'll wager you have that advice on a shirt.
I really enjoyed the video, a lot of good information delivered in an easy to understand manner. Your work is very professional. You made the comment that you talk a lot, well I am glad you do. All your talk was very useful information. I am using the same Tesla battery cells and it was great to see how you made the boxes. I see you mounted the battery cells in thier edge, exactly what I plan to do. Thank you so much from West Australia.
You aren’t sneaking the “things go in and out a little easier with some lube” and “everything’s safer with a little rubber” 😂
This guy can actually start an bad-ass Ev company and everybody will absolutely love it.
Tough competition to Elon ❤️
15:30 you can get machine taps that keep a continuous chip which exits from the rear.
Gun taps are what you’re referring to, but roll form taps work best in soft materials such as aluminum. They “push” the material into the thread form rather than cutting it retaining its grain structure and strengthen the threads.
It is coming along nicely. Can't wait to see the finished Humvee rolling down the road under its own 440 v power. Thanks for sharing.
Very intresting video. You are very good to explaining the whole system. I understood and gave me very good details of the power, circuit board and how things works. Amazing Cheers.
Hello friend how are you ?