He Works at an Auto Shop That Does EV Repairs, and They Had a Client Bring a Custom Built 1993 Humvee for a Full Electric Conversion

An auto shop technician with the handle Gaming Hunter gave a recent account of a customer who brought their 1993 Humvee in so it could be converted to an electric vehicle. In the Reddit post, he indicated, “I work at an auto shop that does EV repairs, and we had a customer bring us their custom-built 1993 Humvee converted to full electric”. First off, it is technically feasible to do so. While classic vehicles are commonly considered for these conversions, electrifying an old-school Humvee presents a unique set of challenges.

For one, such a conversion is not as common for military-grade vehicles like the 1993 Hummer. They are significantly heavier than most vehicles, so the battery weight and motor would have to be above average for the change to make sense. Similarly, the original chassis design was not intended for an electric powertrain, so the modification would have been quite complex. Despite these issues, some enthusiasts, like JerryRigEverything on YouTube, did the exact HummerEV conversion. 

What it Means to Convert a Hummer to an EV

EV conversions typically follow a structured process entailing the replacement of internal combustion parts with an electric powertrain. The first step is to remove the internal combustion parts on the vehicle, such as the original petrol or diesel engine, exhaust systems, or gearbox. Hummers' large engines provide significant space for the batteries and motors. The shop must also select a suitable motor according to the Hummer's weight and performance requirements. Permanent magnet motors are an option, though these tend to be costlier. 

Alternatively, they can install an AC induction motor widely used in EV conversions. Given the Humvee’s weight, a high-torque motor is essential to maintain the intended performance. 

The battery pack is also an essential component in the EV conversion. Among the factors to consider is the capacity. The battery should be able to give the required range for practical use. This Humvee would need between 80 to 100 kWh to achieve sufficient range. Weight distribution is also a consideration since the battery adds weight to the vehicle. Battery packs may be obtained from EV manufacturers or salvage yards, which are significantly less expensive.  

The next step is installing a controller and inverter. This regulates power from the battery to the motor. A high-performing controller would be required to handle its power demands. If using an AC motor, the inverter converts the DC power to AC for the motor. A charging system is also relevant. That includes an onboard charger, a DC Fast Charging connection, and potentially regenerative braking. An onboard charger converts AC from the wall outlet to charge the battery. DC  fast charging is optional, but it would be great for fast charging. 

Regenerative braking is also optional, but it would improve efficiency by converting the braking energy back to electricity. As the battery pack adds additional weight, an upgrade to suspension and braking is also needed. That may entail reinforced shocks and high-performance braking to improve the vehicle's handling following conversion. A customized battery management system would also improve performance. This system monitors the charge levels and overall battery health. 

Potential Issues with Converting a Humvee

Humvees were initially made to be huge lumbering vehicles, and electric powertrains also come with significant weight. Managing this without having a compromise on the acceleration afterward requires careful planning on the battery or motor placement. Due to the power demands and overall size, a Humvee might not achieve the long-range typical current EVs. 

Considering the aforementioned requirements, it is easy to surmise that conversions are expensive. A complete conversion may cost from $50,000 to $150,000, depending on the vehicle. This includes the parts required and the labor involved.

Since Humvees require powerful motors and high-capacity batteries, the cost will be on the higher end of that scale. JerryRigEverything's conversion cost $100,976 in total. The truck was assembled from both salvage and custom service platforms. The most expensive part of his build was the motor and drivetrain. A brand new UQM 220 plus inverter and motor cost him $25,000. The YouTuber also made several adjustments to the body and cabin as per preference. 

Truth be told, such a conversion, as ordered by the client in the Reddit post, would cost significantly in terms of the parts and manpower involved. This is compared to the current MSRP of a 2025 Hummer EV, at $98,845. On paper, it makes more sense to purchase a new EV, but an enthusiast could be forgiven for valuing the novelty of the older version. At the end of the day, if you have the resources and time to make it work, by all means, go ahead. 

Image source: r/HummerEV Reddit Group

Nicholas Muhoro is an automotive journalist covering car news and has a decade of experience sharing working at HotCars and TopSpeed. You can follow Nicholas on X and on LinkedIn to stay in touch and follow his news coverage at Torque News.