Want a Ride? - My Electric Hummer Battery is MOUNTED!!

today's a pretty big video we are taking all of these battery boxes and putting them in the Hummer the hardest part of this whole project and I kid you not is finding plugs for this middle battery box we have wires needing to leave all sides we have this big plug right here for the two out wires going to the motor in the front then we have a gaggle of communication wires that need to go out the back side so while finding the correct plugs was extremely difficult I think I did find some that'll work and hopefully this all works out up to this point we've been tethered by the two watt cables going up to the Humvee giving us a drivable range of about three and a half feet so today once everything is connected and in the Hummer with their plugs we'll be ditching the tether completely and we should be able to pull completely out of the garage this video is sponsored by kiwico more on them later and we also have official whisper project t-shirts with whisper project on the front and all of the specs of this massive Hummer on the back you've seen all the videos and now with the shirt you'll have proof that you were here when it happened I'll leave a link down in the description for those and now we have a huge project ahead of us because these batteries aren't going to move themselves let's get started [Music] [Applause] [Music] the first plug we're using is a Canon plug from the HD 30 series and this guy can handle 30 wires coming out of it from the BMS and the relays attached to the contactors there was one website that was decently good at pairing up male and female plugs and that's wirecare.com not sponsored they just have a really good plug assembly website that is much better than everyone else's now we just have to disassemble the center box add the plug and start populating the wires foreign [Music] obviously a smart person would have pre-planned and drilled these before assembling the battery box but I am not a smart person and this is my first time building an electric vehicle which is why we're drilling the plug holes after the fact we're making this up as we go you might be thinking to yourself hey Jerry if the boxes are watertight how do you compensate for the thermal expansion of the modules as they heat up and that's a fantastic question we're doing that with this guy it's called a breather valve inside of this little guy is a semi-permeable membrane which means it can be completely submersed and then you know pulled out of the water and still breathe so it'll keep the boxes water tight while allowing hot air to escape and keep the inside of the boxes equilibriumized to add the Breather valves all we have to do is drill a hole in the side of the box and tap [Applause] tapping the 3 16 aluminum on the back side of the Box allows us to thread the valve in after it's been assembled which you'll see in a second so you've seen this part but you have not seen what's back here and I promise I'll make a whole video explaining how we did the cooling system but a brief short explanation is that coolant will come in one of these lines cycle through the battery and exit out the side I'll go into way more detail in a cooling video after we get this battery mounted if you remember we have lasered out half inch aluminum panels to be the tops of each of these three boxes but we haven't quite figured out a way yet to get the boxes from this table into the Humvee according to my math they're going to each weigh about 400 pounds which isn't something you can just pick up but I think I do have a solution and we're gonna do that with an industrial grade dual armed orthogonally constrained tapping machine with over 350 pound-feet of torque this bad boy is able to tap up to an inch and a half hole which is insane obviously we're not going to use inch and a half today on our project we just need holes for an eyelet so we can hang the box from my engine hoist and bring it over to the Humvee I'm here to get an ash cut you know wash cut has the lasers and massive bending machine but they also have this [Music] which makes it super convenient to tap holes inside of thick pieces of metal now I won't have to do it myself of course I won't say no to trying out this Beast of a machine though [Music] and just like that our holes are drilled and tapped oh so each of these battery modules has plastic ridges along the top and we've laser cut slits into this top plate and they will sit down and hold the module secure forward and backward as well as left and right just for the record we have installed the two watt cables onto their Terminals and we've also insulated the ends so as we feed them through the box there is no live bare metal connections and they're safe to touch then the Box itself is slid down over the top plate it's a pretty snug fit and this unfortunately means that the orange high voltage bus bars are going to be covered up as well as the blue water cooling manifold in the back which is unfortunate because those do look pretty awesome but since you guys have watched the video you'll know what's inside of the boxes things will be much safer when they're contained protected to seal the Box up and make it watertight we're using something called RTV gasket making silicone this applies as a thick liquid and then dries and solidifies to help keep water out kind of like what we saw inside of the Galaxy fold 3 how they sealed inside of their hinge we're using the same thing on this battery box we'll be gooping it on nice and thick but these battery boxes won't be seen so it might not be super aesthetically pleasing at the moment but at least they'll be watertight [Music] once the sides are in place we can take some half inch screws and screw into the half inch slab of aluminum at the bottom and the top [Applause] and there we have it one of the three boxes is now assembled quick peek inside so you can see how it works we will have these two watt cables going out through the conduit to reach the other boxes we have the terminals insulated the cables insulated the bus bar is insulated and then over here where we have the cooling come out we have these little rubber grommets that are screwed into the side of the frame once again there to help keep water out now I think the last thing we have since these little eyelets are screwed in is just taking this box plopping it behind the driver's seat should be pretty easy we'll see how it goes [Music] [Applause] [Music] before we can set this box in the Humvee though we do have to weigh it now this box has enough power inside to run a house an entire house here in the USA for one day so let me know before we weigh it down in the comments how much you think it weighs foreign because I have it right here just shy of 500 pounds not too shabby now let me know also down in the comments how close you were to your guests it's hard to calculate that much energy enough to run a house for a day but inside of this Humvee we have enough energy to run a house here in the USA for three days but not unless we actually get these batteries in which is now we also took a sheet of adhesive Rubber and lined the battery box in the spots where it might come in contact with the Hummer frame to isolate it from vibrations as well as to isolate each of the boxes from each other it might be a bit Overkill but you know when you're working with this much power Overkill is a good thing foreign [Music] [Music] [Music] [Music] period [Music] and there we go one of the three boxes is in and you can kind of see how things are going to work with the two watt cables and the data coming out through the conduit into the middle and side boxes I'll go through how we mounted it to the back when we do the passenger box now that we've done one the other one should go slightly quicker and then we have to finish off the middle box but we are so close I can almost feel the wind through my hair so right now I am standing where a battery box should be and it's time to wire up a plug to our inverter remember we're taking the DC power from the batteries and turning it into AC with a two watt cable Bridging the two and that two watt cable needs a plug one cool thing about the wires we're using is that they are shielded meaning that there is a metal mesh over the copper conductor and that metal mesh is grounded to the low voltage 12 volt system and gets rid of some of the frequencies coming off of the wire as power is flowing through it so it doesn't disturb our sensitive Electronics like our display and can system the plugs I'm using have the same voltage and more importantly amperage rating as the two watt wires that I'm using and through a complex system of metal doohickeys rubber grommets and crimped components our two out wires are successfully inserted into a plug all right moment of truth everything is connected this is the side that's gonna go into the battery box uh Jeremy's gonna put it in done we now have a high voltage plug as far as mounting the aluminum boxes to the frame of the Humvee we've lasered and tapped a mounting plate which gives us more thickness and a solid spot for the bolts to thread into and hold it tight pinching the beam that's supporting the whole thing it's time for the passenger box [Applause] the Sheets Were taping to the side are called Mica sheets these are sitting on top of the modules inside of the original Tesla battery they're designed to be a good insulator and speaking of insulators each one of these modules has a piece of plastic a sliver of air and another piece of plastic separating each one it's important as we're driving down the road that none of them will actually be touching each other or jostling around the box is tight enough to keep any friction from happening to the modules and the mica sheet along with the layer of plastic is there to keep it from coming in contact with the edge of the Box we're pretty safe in there foreign [Music] foreign [Music] [Music] [Music] foreign [Music] [Music] foreign then was the boxes in place we can take the bolts along with a washer insulated grommet and slide it through into that bolt plate we left there earlier [Music] [Applause] foreign [Music] so it's time to wire up all these super fine tiny wires inside of the main high voltage junction box the middle battery box what we're using is this Canon plug with 31 holes in it it's called an HD 30. and the part we're mounting on the box has a flat part on Top which keeps it from rotating when it's sitting inside of that middle box [Music] there's a lot of little wires in here but they're all relatively super kind of important luckily these are super easy to use and I'll show you how so this is Jeremy and he's been wiring up the plug we're pretty close to done but there's a couple left this is the little pin that goes inside of the Canon connector the receptacle slips over the wire and gets crimped into place with a special crimp that pinches it on all four sides so it's super easy just push this in and wait for the click that was it that was it so right now I'm just wiring up the two watt cables that go to the plug leading outside of the box and one of the things I really like about this crimp is that it actually leaves an imprint of what it's crimping on the actual lug let me show you if you look on the back here really close you can see the little two watt kind of tattooed onto the lug there and that's one of the ways you can tell that the lug is solid once again I'm not an expert in any of this I'm just doing it and pretending like I know what's going to happen foreign [Applause] [Applause] before we set the center box in you will be pleased to know that I did clean up all the wires in the truck bed as well as organize the wires underneath the hood they're not in their final placement yet sheathed in that plastic but I did take some Linus Tech tips velcro ties and get them in the general spot where they're going to be when it's all finalized I think Linus thought that they were going to be used for computers and desks but here they are in an EV conversion when everything's finalized I'm going to be sheathing all these cable strands and wires inside of this a protective plastic cover that keeps everything super protected but before we can do that we have to make sure everything works two of the three boxes are in the Humvee it's time for the center and final box foreign foreign that looks good foreign [Music] so we've weighed the two side boxes each of them weigh about 480 pounds the center box is going up put your estimates down in the comments we are looking at 324 pounds as it's completely suspended off the table we should probably put that back down so doing the math which I'm not an expert at it looks like we have right around 1300 pounds worth of batteries it'll be really interesting when we get to the end of this and we can see the weight difference between what it originally had and everything I've put into it foreign [Music] [Music] thank you so we finally have all three boxes in place and it looks amazing I'm a little biased but let me show you how we're gonna join them up because each of the boxes has two pieces of these orange cables going through along with the data cables and they're all passing through with this piece of conduit now this is really stiff I can barely move it with my fingers because it's cold but if we open this up we have one that's been cooking and it is extremely soft and supple and ready to be added between the boxes and now we have a perfect pathway for the two watt to sneak through the watertight conduit into the center box foreign foreign I think it's finally time to see if this rolls but quick let me show you what's inside the center box I might be stalling a little bit but just so you can know how it works from the inside my view for back here looks pretty amazing obviously we have the electric motor up there the negative most battery on this side positive most battery on this side and this is what's controlling all of our power and once the contactors are clicked energy can flow out through the cable that we made the plug for into the inverter and to the motor and with all of that power so eloquently controlled in that Center box it is time to turn the key we've been working on this project for well over a year now and there's so many different parts of this puzzle it's it's weird to see it all come together right now let's see what happens foreign there this time we're gonna do it for real turn the key and we're gonna listen got that first click second click I think this is drivable before we go anywhere though it's night time and we probably need some headlights we're putting the hood back on an electric motor brought it into the garage and an electric motor will be the thing that brings it back out [Music] it is time for a midnight drive I think all the settings are right um this could be a very interesting Drive [Music] yeah it's been a while since we've cleaned the windows on this thing there's a parking lot right next to my house we're gonna pull in it's so sick dude yes it takes a minute to get used to for sure oh this is crazy this is the first time this has moved in years wow wow all right so the torque box is a little louder than I anticipated but that like whining noise like it's that went away which was interesting like that went away after just a couple minutes it was back so it must be like when you're when you're going really slow all right first impressions here on my very first drive we haven't gotten the settings totally dialed in yet honestly it's a little bit noisier than I thought it would be um but it is incredibly fun to drive I think we need to dial some more stuff in with the VCU but it's amazing that it's actually moving it's literally been sitting in my driveway for two years as we've planned this and for one year in my garage as we've been putting it together the videos might make it seem like it looks easy but it's actually been like a hundred hours per video that we've made it's taken a lot of time but so far I'm super happy it's a very a unique ride that I've never you know driven before and we can't go very far because we haven't hooked up the cooling system yet it's winter so I'm not super worried about it the batteries aren't going to overheat but I am worried about the motor and inverter so we can't go super far we will do that in a future video along with taking it on a more you know off-road Real World Drive hopefully by then we have everything dialed in but it is super exciting what do you think Jacob yeah those brakes worked great what about the rest of it uh yeah it's I mean it's kind of hard to drive with one hand we haven't gotten the brake switch added to the pedal yet so we're just manually controlling it we are in a parking lot though that's what parking lots are for thank you [Music] again dude doesn't look weird face in that direction I think it does a little bit I mean obviously there's a lot more we need to do is just the first drive um it was struggling a little bit when we first left the garage and then we punched a random number torque wise into the VCU and is working fine but there's a lot more we can dial in this whole thing has just been a massive learning process for me this is the very first electric vehicle I've ever built and one really cool thing about learning is that you can do it whenever which brings us to kiwico kiwiko's mission is to provide the next generation of innovators with the tools and the foundation to become creative problem solvers and critical thinkers they do that with fun monthly Hands-On projects and activities like this one about slime circuits turns out when you add borax and glue to water you get some cool looking slime that actually conducts electricity and makes little circuits it is infinitely safer to learn about electricity using slime circuits than it is building your own electric vehicle it's a lot cheaper too these monthly crates are designed by experts and are a great resource for learning at home it's super fun there are eight different subscription lines catering to different age groups and topics from Toddlers to teens all the way to adults my wife still gives out these subscriptions as gifts for holidays or birthdays and my nieces have a lot of fun with them and personally I think these steam projects science technology engineering art and math are a lot more fun when it's Hands-On that's my favorite but you don't have to take my word for it though they've shipped over 30 million crates and you can get your first crate for free with the link down in the description kiwico.com jerryrig so while the Hummer is indeed now mobile there are still quite a few things we need to do on it like add cooling so we can drive farther than just my neighborhood as well as make sure everything's programmed and working nicely together and then we can take it out for a real drive this is going to be a work in progress for the next long while so if you haven't hit that subscribe button would appreciate it if you did hit that notification so you don't miss any future uploads come hang out with me on Instagram and Twitter sometimes there's sneak peeks over there and as always thanks Tom for watching and I'll see you around

Channel: JerryRigEverything

Views: 1,692,808

Keywords: Electric Hummer, EV Hummer, Hummer EV, Electric truck, electric conversion, electric vehicle, EV, cybertruck, tesla, rivian, ford lightning, electric hummer conversion, tesla battery module, electric hummer, hummer ev, gmc hummer, ev hummer conversion, ev hummer, Electric HMMWV, electric humvee

Id: gidJopKtcnc

Length: 31min 10sec (1870 seconds)

Published: Sat Feb 19 2022