The world of electric vehicles (EVs) is witnessing a surge in interest around extended range electric vehicles (EREVs). While major automakers are developing future models, enthusiasts like Simon Lindley of the Trucked Up EVs YouTube channel are finding innovative ways to enhance the capabilities of existing EVs.
Lindley’s latest project involves transforming his Ford F-150 Lightning into a DIY EREV by integrating portable battery banks. This ambitious endeavor aims to address range anxiety a common concern among EV owners, by enabling the truck to recharge while in motion.
How the EverDrive System Works
The heart of this modification is the EverDrive system, a prototype that connects directly to the vehicle’s high-voltage system. Unlike conventional methods that might involve plugging into the charge port while driving, EverDrive adds an auxiliary J1772 port to the vehicle.
For the Ford F-150 Lightning, Lindley installed the port in the truck bed by drilling a hole in the bed liner and routing the power cables beneath the vehicle. These cables are then connected to the EverDrive prototype located at the front of the truck. The system integrates with the truck’s onboard chargers using a series of relays and a microcontroller.
The Role of the PEAK Microcontroller
The brain of the EverDrive system is a microcontroller manufactured by PEAK. This microcontroller sends custom-programmed CAN messages to the truck, which, in conjunction with the relays, enables the system to charge the vehicle while it is being driven.
Testing the System with Bluetti Batteries
Once the EverDrive system was installed, Lindley packed the truck bed with Bluetti battery packs totaling 16 kWh of additional power. He then embarked on a test drive to evaluate the system’s performance.
It’s important to note that this project is not a budget-friendly endeavor. The battery system alone cost approximately $7,500, though Lindley managed to secure it for around $5,300, or 7,499 CAD. The EverDrive system, which is not yet available for purchase, is expected to retail for about $2,000 when it hits the market.
In total, the project cost Lindley around $9,500 for an additional 15.8 kWh of capacity, not including the solar panels he uses to recharge the batteries. For comparison, the canceled Tesla Cybertruck range extender was estimated to cost $16,000 for 47 kWh of battery power.
Challenges and Results
The test did not go entirely as planned. Lindley encountered issues with the battery storage configuration, which did not drain as expected and became imbalanced. This imbalance left about 8% of the Bluetti’s power unused.
Despite these challenges, Lindley’s efforts were not in vain. He analyzed the data to determine how much additional energy he was able to utilize from the batteries and the corresponding increase in range. According to his calculations, the battery setup provided approximately 55 km of extra driving range.
The Potential of the EverDrive System
While the additional range may not seem substantial, the true value of the EverDrive system lies in its potential to open up the Ford F-150 Lightning’s ecosystem to the aftermarket community. This innovation allows enthusiasts to experiment with modifications that could prove beneficial in emergency situations.
The question remains: Is the EverDrive system worth the nearly $9,500 investment? The answer depends on individual priorities, but the cool factor and the potential for future innovations are certainly compelling.
