Episode 4: Where Should the Battery Pack Be Installed?
In Episode 3, we showed how our engineers designed the custom adapter plate and coupling system to connect the electric motor to the original Toyota Hilux manual transmission. That mechanical interface is the foundation of a reliable EV conversion.
But once the motor has a place in the vehicle, another engineering challenge immediately follows:
Where exactly should the battery packs go?
Unlike the motor, batteries are not a single component. They are usually divided into multiple modules, and their location affects almost every aspect of the vehicle—from weight distribution and handling to safety, maintenance, and driving range.
In Episode 4, we walk through the planning process behind battery placement before any battery boxes are built or installed.
🎥 Watch Episode 4 on YouTube:
https://www.youtube.com/watch?v=dmDI3fUf8AM&list=PLH_S-bVz1dh8&index=4
Battery Layout Is More Than Finding Empty Space
One of the biggest misconceptions in EV conversions is that batteries can simply be installed wherever there is room.
Professional battery packaging requires balancing multiple engineering factors, including:
- Vehicle weight distribution
- Chassis strength
- Ground clearance
- Suspension movement
- Cooling and ventilation
- High-voltage cable routing
- Maintenance accessibility
- Future serviceability
A well-designed battery layout doesn’t just improve reliability—it also makes the vehicle safer and easier to maintain.
Measuring Before Building
Before designing battery enclosures or mounting brackets, our engineering team carefully measures every potential installation area on the Hilux.
In this episode, we evaluate:
- Engine bay dimensions
- Chassis rail spacing
- Underbody clearance
- Cargo bed space
- Existing mounting locations
- Suspension and drivetrain clearance
These measurements determine how much battery capacity the vehicle can safely accommodate without compromising structural integrity or practicality.
Choosing the Right Battery Locations
Every EV conversion is different, and there is no universal battery layout.
For the Toyota Hilux, possible battery locations include the engine bay, underneath the cargo bed, or a combination of both.
Rather than concentrating all battery modules in one place, distributing them across multiple locations often provides:
- Better front-to-rear weight balance
- Improved handling
- Lower center of gravity
- More efficient use of available space
- Easier future maintenance
The final layout always depends on the customer’s required driving range, payload, and vehicle usage.
Designing for Reliability
Battery installation isn’t just about fitting batteries into the vehicle.
The design must also consider:
- Battery enclosure protection
- Water and dust sealing
- Vibration resistance
- Cooling airflow
- High-voltage safety
- Ease of maintenance
These details may not be obvious once the vehicle is complete, but they have a significant impact on long-term reliability.
What’s Coming Next?
Now that we’ve finalized the battery layout, it’s finally time to unpack the complete EV conversion kit.
In Episode 5, we’ll introduce every major component that powers this Toyota Hilux EV conversion—from the electric motor and controller to the wiring harness, charger, DC-DC converter, accelerator pedal, and more.
Planning Your Own Hilux EV Conversion?
Every EV conversion is unique.
Choosing the right motor, battery, controller, and transmission configuration depends on how the vehicle will be be used.
At GMT, we’ve already helped customers electrify vehicles such as the Toyota Hilux, Isuzu D-Max, and other commercial vehicles. We’re also documenting our own Hilux EV conversion project step by step to share the real engineering process behind a successful conversion.
If you’re considering converting your own pickup truck, we’d be happy to help.
Simply contact us by [email protected] with your vehicle details, and we’ll provide a preliminary Bill of Materials (BOM), recommended system configuration, and an estimated project budget based on your project requirements.
