Here is Lanny’s work on putting Hi Power Lithium modules into Ford Ranger EV’s .

He’s really moved the Rangers ahead and out of the hands
of a terrible fate. I’ve exchanged a lot of email with him as I’ve
worked on Rangers. I’m hoping he has a good BMS picked out or on the
design board.

I’ve had the Thundersky equivalents of those Hi Power cells that Lanny
is using. The Hi Power’s that he is using I have ordered and will
arrive next week for testing.

The issue for us is how will lithium function in a real EV. Bench
testing has major limitations compared to real world. Real world
driving beats on batteries like no bench testing ever could.

I’m also in a group that has a working Lithium BMS that is being
majorly tweaked at the moment. It has no street time yet, but will
soon. I was suppose to have some street time already but this second
truck has taken all of my energy.

The good news for us is that a small or medium pack will fit our
trucks fairly easily. My nicad pack is about 1400 lbs lighter than the
bone stock Hawker pack. The Lithiums would be 1800 lbs lighter than a
bone stock Hawker pack. But each of the 100 cells has to have a BMS
module. All of those 100 cell modules have to talk to a master to keep
the driver informed.

The good news about using around 100 cells is that our chargers can be
tweaked to handle lithium. I’ve done it. The max voltage output of our
chargers is 400vdc. 100 cells could only charge to 4.0v each. 3.6v to
3.8v has been suggested. The 400v limit will help keep from
overcharging the cells. But they still have a mandatory requirement
for a BMS.

108 40ah cells would fit easily. 100 60ah cells will fit nicely. About
100 90ah cells with a second batt box will fit. The range due to the
light weight would be great. The lifespan in an EV has only been
tested to 25k miles. Then they were accidentally discharged overnight
and ruined in the blink of an eye.

40ah pack = $6.9k. 60ah pack = $9.6k. 90ah pack = $14.4k. All of these
prices are without a BMS. Right now a BMS looks to be $1.5k+ if you
assemble it your self.

There may be cold weather issues as was reported by a lithium user
some time ago. So testing is everything because toasting these babies
is vastly more expensive than buying the truck in the first place.

You’d think this format of Lithium would fit in the Prizm’s nicely.
But I have never heard of anyone trying.