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Hybrid Truck Video

New Troop 51 web page

This project cost me about $10,000 or about the same as a good turbo charger.  I am sure costs have changed since I have done the project but you can use this as a rough guide of what is involved and the costs of each subsection.

Below are the parts used in the conversion.  Costs could be reduced using 4 large batteries for a 48V system.  I am using 12 batteries for a 72V system.  Data will tell if the extra costs for the higher voltage is worth it.

Parts List

  Number Cost Each   Total
Charging System        
Dual Pro chargers 3-6 amp chargers 4  $    183.12    $     732
Shipping 1  $      22.00    $       22
Retractable cord 1  $      67.10    $       67
Power cords to chargers 2  $       7.95    $       16
Power Strip for chargers 1  $       6.00    $         6
       
Controller         
Altrax - 7245  1  $    600.00    $     600
TIMS Programming Unit 1  $    500.00    $     500
Computer interface diagnostic unit (EMIS) 1  $    500.00    $     500
Contactor with resister & diode & shipping 1  $    151.67    $     152
Low voltage contactor to shut off controller. 1  $      15.00    $       15
Rabbit EMIS programming module 1  $    103.26    $     103
Dash Switches for contactor & EMIS 2  $       3.00    $         6
0-5K Throttle pot 1  $      87.20    $       87
Shipping for EMIS & Altrax 1  $      16.25    $       16
       
Wiring         
Battery Cables #2  12  $       6.95    $       83
Cable 1/0 Welding wire  ft. 26  $       3.95    $     128
Lugs 1/0 with shipping 12  $       3.03    $       36
12 gauge lugs (boxes) 1  $       4.95    $         5
14 Gauge wiring ft 50 $0.08    $         4
12 gauge wiring ft 60 $0.13    $         8
18-12 gauge connectors & terminals 12 $0.50    $         6
1/2" Spiral wire wrap 20 $0.93    $       19
Heat Shrink Tubing 1 $17.13    $       17
Main power fuses 400 & 200 amp 1 $66.60    $       67
Fuse Holders 12 $1.02    $       12
Fuses 7.5 amp 12 $0.07    $         1
Wire ties - large 14" 15 $0.25    $         4
Wire ties - medium 6" 25 $0.10    $         3
Terminal blocks 2 $6.00    $       12
2 gauge Anderson quick disconnect 1 $24.22    $       24
Electrical tape 1 roll 1 $5.00    $         5
       
Motor        
NetGain TransWarp7 1  $ 1,375.00    $   1,375
Slip Yoke from NetGain 1  $    175.00    $     175
Tail shaft housing  1  $    150.00    $     150
Shipping 1  $      97.96    $       98
Bolts for housing 6  $       0.30    $         2
Housing gasket & and grease fitting 1  $       5.50    $         6
Shorten & balance main driveshaft 1  $    385.00    $     385
Rework main driveshaft for new motor 1  $    108.00    $     108
Build 6" driveshaft - FleetPride 1  $    125.00    $     125
Bracket to hold motor front face 1  $    165.00    $     165
Galvanized pipe for rear motor mount 1  $      65.00    $       65
Frame welding for rear motor bracket. 1  $      30.00    $       30
Shop time to install motor 4  $      50.00    $     200
Spare driveshaft from junk yard 1  $      45.00    $       45
1/4" Key 1  $       5.00    $         5
Misc bolts and washers (Fastenal) 1  $      42.37    $       42
Transmission Mount for tail housing 620-1241 1  $      18.00    $       18
Isolated Mount Bushings & shipping 8      $       36
Rubber spacers (602-1045) & brackets 1  $    110.10    $     110
       
Batteries        
Batteries - Thundersky 40 amp-hr  12  $    220.00    $   2,640
Rivets (boxes) 2  $       5.00    $       10
Powder coating of battery boxes 1  $    125.00    $     125
Battery box fabrication 1/8" Al 2  $    150.00    $     300
Decals - Safety for EMT workers 3  $       3.50    $       11
    Total    $   9,481