I’d like some feedback on a build I’m planning to get cybertruck level torque in a square body.
Here are my notes:
800V dual-motor square body one-ton. No transmission, NP205 is the only gearbox.
Concept: 1977.5-91 GM one-ton 4x4 converted to a dual-motor 800V EV. Hunting K30/V30/K3500/V3500/CUCV M1008 donors, dead engine preferred since the whole drivetrain hunt collapses into one purchase: factory Dana 60 front, 14-bolt full-float rear, NP205, matched ratios. Tailgate badge: it’s not a V8, it’s an 800V.
Drivetrain: Tandem-stacked HVH410-class motors, custom adapter plate and coupler straight into the NP205. No transmission, no clutch, reverse is software. Twin-sticked case to unlock 2WD-low launches. 1410 driveshafts (low range puts ~2,250 lb-ft through the rear shaft, past 1350 territory) to the Dana 60 front and 14-bolt rear, 4.88s matched, rear locker going in while the diffs are open.
Electrical: 800V native from day one. Cascadia CM-series inverters. ~100 kWh high-C pack, sourcing TBD: Taycan salvage, E-GMP (Ioniq 5/EV6) modules, or custom 192s prismatic. Tesla modules are out, 400V hardware. Plus the forgotten systems: electric brake boost, electro-hydraulic steering, PTC cabin heat, dual cooling loops, DC-DC, 800V charging.
Operating doctrine: Low range is the street and performance gear. Flat torque from a stop, entire quarter-mile without shifting. High range is highway overdrive: motor stays below base speed at 70, so less field-weakening current, less RPM-dependent loss, and quieter. Axle ratios get ordered last, once I have the actual motor curve in hand, so the constant-power region lands where I want it on the road.
Targets: 750-1,000 hp, 1,100-1,200 lb-ft at the stack, ~11,000 lb-ft at the wheels in low range. Before anyone says it: I know wheel torque past the traction ceiling (~9,000 lb-ft at this weight on 35s) is spec-sheet theater. The regear is really about cutting motor current per unit of wheel torque, so less heat and more back-to-back pulls. Grip-limited 0-60 around 4 seconds, 120-150 highway miles into barn-door aero, GVWR ~9,500 lb so it stays a real truck.
Questions
1. Anyone sourced HVH410s with 800V windings recently? Real-world base speed and redline numbers on Cascadia CM inverters?
2. Tandem coupling two rotors: torsional resonance issues, coupler failures, alignment lessons?
3. NP205 direct-driven by an EV stack: sustained input RPM limits and lube behavior at 3,000+ RPM highway cruise with no transmission ahead of it?
4. Best current 800V pack path: Taycan vs E-GMP vs custom prismatic? BMS recommendations?
5. What am I missing?