Random pic thread.

Been 5 years since I replaced the batteries on the electric SXS and they are starting to get weak again. Last month one of the good vendors was running a sale on lithium conversions, so I decided to bite the bullet.
Replacing 750lbs of batteries
IMG_8803.jpeg

With 190lbs of batteries
IMG_8806.jpeg


First step was to pull it all out
IMG_8865.jpeg


And of course once it was out, I saw just how bad it has gotten in the last 5 years
IMG_8867.jpeg
IMG_8868.jpeg


It looks funny with everything out and the plastics off.
IMG_8874.jpeg


After a bunch of grinding and wirebrushing and pressure washing, then a coat of Rust Reformer it started to shape up.
IMG_8875.jpeg
IMG_8878.jpeg


One of the battery trays completely crumbled when I tried to remove it. The other was good enough for a pattern.
IMG_8870.jpeg
IMG_8871.jpeg


Having never cut aluminum with the plasma before, I didn’t know what I was getting into, but 27amps and some air worked great.
IMG_8879.jpeg
IMG_8880.jpeg


Then needed to add the tabs for the plastic to mount to.
IMG_8883.jpeg
IMG_8888.jpeg


Overall I’m thrilled with how everything came out. Installing the batteries and charger should be the easy part, but I ran out of time today haha. Also doing a SuperATV power steering conversion and recovering the seat, so this puppy should be good to go another 15 years. Plus this new battery setup will double the range, eliminate the off gassing while charging, and increase top speed by about 10%, not to mention the improved acceleration by losing almost 600 pounds! :D
 
Last edited:
Overall I’m thrilled with how everything came out. Installing the batteries and charger should be the easy part, but I ran out of time today haha. Also doing a SuperATV power steering conversion and recovering the seat, so this puppy should be good to go another 15 years. Plus this new battery setup will double the range, eliminate the off gassing while charging, and increase top speed by about 10%, not to mention the improved acceleration by losing almost 600 pounds! :D
I'll be interested in hearing how it changes the handling, that 600lbs was down fairly low, so this is going to move the center of gravity up by quite a bit. I'll bet the thing is going to be a lot more tippy, especially with 2 people and any heavy payload in the bed... Can you go to a lighter spring if it proves to be an issue?
 
I'll be interested in hearing how it changes the handling, that 600lbs was down fairly low, so this is going to move the center of gravity up by quite a bit. I'll bet the thing is going to be a lot more tippy, especially with 2 people and any heavy payload in the bed... Can you go to a lighter spring if it proves to be an issue?
That was my first thought.
 
I'll be interested in hearing how it changes the handling, that 600lbs was down fairly low, so this is going to move the center of gravity up by quite a bit. I'll bet the thing is going to be a lot more tippy, especially with 2 people and any heavy payload in the bed... Can you go to a lighter spring if it proves to be an issue?
Definitely a valid point, but basically it will make it as stable/unstable as a regular Polaris Ranger. It will go from almost 1800lbs to down around 1200lbs. All of the weight is still pretty darn low, mostly below this line:
1743014666112.png


The only heavy things above the line are the rollbar and bed, and I'd bet everything above the line weighs a total of 200lbs or less. Lighter springs are an option, but I'll start by simply moving the preload adjusters to the lightest setting and see how it does. Many of the guys who have done the lithium conversion talk about a much stiffer ride, which certainly makes sense. I can swap over springs/shocks/struts from a same year 400/500/700 Ranger if I want to change it. But honestly its mostly used on pavement/gravel roads and around the yard, so I don't think it will matter much.
 
Definitely a valid point, but basically it will make it as stable/unstable as a regular Polaris Ranger. It will go from almost 1800lbs to down around 1200lbs. All of the weight is still pretty darn low, mostly below this line:
View attachment 435577

The only heavy things above the line are the rollbar and bed, and I'd bet everything above the line weighs a total of 200lbs or less. Lighter springs are an option, but I'll start by simply moving the preload adjusters to the lightest setting and see how it does. Many of the guys who have done the lithium conversion talk about a much stiffer ride, which certainly makes sense. I can swap over springs/shocks/struts from a same year 400/500/700 Ranger if I want to change it. But honestly its mostly used on pavement/gravel roads and around the yard, so I don't think it will matter much.
Don’t forget your fat ass is above the red line…..probably well above the 200lb mark. I agree, won’t much matter, but thought it was important to point it out anyway. 😜
 
Don’t forget your fat ass is above the red line…..probably well above the 200lb mark. I agree, won’t much matter, but thought it was important to point it out anyway. 😜
Shit he's short and round he can just roll outta the way if it starts to flip
Yall dumb. I’m so short I lower the center of gravity! :p
 
Need to finish assembling the 6.4 for the SRT. Got a full suspension from Ironman for my wife's ZJ. Need to install her 4.7 stroker.
Not taking on more gear work for a while.
Then @Scott86MJ batted his eyes at me.


Then @xjay sweet talked me into regearing his Rubi JK. But he's the last one...😜
 
The only heavy things above the line are the rollbar and bed, and I'd bet everything above the line weighs a total of 200lbs or less.
... aside from the humans in it....
 
A little more progress tonight. Got the trays mounted and the batteries set in place.
IMG_8903.jpeg


Also used the Bluetooth app, and it’s super slick.
IMG_8905.png
IMG_8906.png

IMG_8907.png


Charger mounted in the same location as the stock one by simply drilling 2 more holes in the aluminum mounting feet.
IMG_8908.jpeg


Then I needed a place to mount the SOC State of charge) gauges. Best place for now was a slightly modified TJ front fender flare extension :laughing:
IMG_8914.jpeg
IMG_8915.jpeg
IMG_8916.jpeg
IMG_8922.jpeg
IMG_8923.jpeg

It looks better from a normal overhead perspective, but there was too much glare to see the gauges from that angle. It still needs a little squaring up on the bottom too.

I need to decide on final positioning for the batteries and punch those 4 holes, then connect the power leads and I’m ready to test drive! :D
 
A very good friend of mine from Alabama is on the Chevy tailgate tour and he was in Denton today, so I went to see him. Took a few pics

IMG_20250327_144111267_HDR.jpg
IMG_20250327_144112651_HDR.jpg
IMG_20250327_140654268_HDR.jpg
IMG_20250327_140649479.jpg
 

Attachments

  • IMG_20250327_135809067.jpg
    IMG_20250327_135809067.jpg
    241.5 KB · Views: 22
  • IMG_20250327_135813464.jpg
    IMG_20250327_135813464.jpg
    96.8 KB · Views: 21
  • IMG_20250327_135817422_HDR.jpg
    IMG_20250327_135817422_HDR.jpg
    165.9 KB · Views: 21
  • IMG_20250327_140415347_HDR.jpg
    IMG_20250327_140415347_HDR.jpg
    210.8 KB · Views: 19
  • IMG_20250327_140424684.jpg
    IMG_20250327_140424684.jpg
    227.2 KB · Views: 18
  • IMG_20250327_140432926_HDR.jpg
    IMG_20250327_140432926_HDR.jpg
    97 KB · Views: 18
  • IMG_20250327_140436335_HDR.jpg
    IMG_20250327_140436335_HDR.jpg
    89.1 KB · Views: 17
  • IMG_20250327_140531591.jpg
    IMG_20250327_140531591.jpg
    215.6 KB · Views: 19
  • IMG_20250327_140645280.jpg
    IMG_20250327_140645280.jpg
    141.1 KB · Views: 22
  • IMG_20250327_140604997_HDR.jpg
    IMG_20250327_140604997_HDR.jpg
    255.7 KB · Views: 18
  • IMG_20250327_140539001_HDR.jpg
    IMG_20250327_140539001_HDR.jpg
    251.9 KB · Views: 17
Back
Top