I'm working on a project that pairs a classic Hemi block with an electric torque assist system, and I'm trying to nail the overall integration strategy. Specifically, I'm curious about the best way to manage torque blending during low‑speed launch versus steady‑state cruising, how to size the battery pack and motor for smooth power delivery without overloading the crank, and what cooling scheme works best for both the internal combustion side and the electric components. Any proven methodologies, simulation tools, or rule‑of‑thumb calculations you rely on would be a huge help. How do you approach this balance in your builds?
Best practices for aligning a Hemi engine with electric torque in a Zodiac build
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I tackled a similar Hemi‑plus‑e‑torque build a couple of years back on a ’68 Charger project. The key was to let the electric motor handle the first 0‑30 mph, so I programmed a torque‑blending map that caps the ICE’s output at 150 Nm until the RPM hits 2500, then gradually hands the load over to the Hemi. I used a dual‑loop controller (one loop for launch, one for cruising) and tuned the transition point with a simple MATLAB Simulink model – the “torque‑vectoring” block makes it easy to see how the curves intersect. For the battery, I went with a 12 kWh 400 V pack split into two 6 kWh modules; this gives enough current (≈800 A peak) for a smooth launch without spiking the crank’s torque limit, and the modules stay under 60 °C thanks to a liquid‑to‑air heat exchanger mounted on the front subframe. On the cooling side, I kept the Hemi’s traditional coolant loop but added a small glycol‑to‑water heat exchanger that pulls heat from the electric motor housing and dumps it into the same radiator, so both systems share a single large radiator plus an auxiliary electric‑driven fan for low‑speed bursts. The whole setup has been rock‑solid – the launch feels instantaneous, and once you’re at highway speed the ICE takes over cleanly, with the electric motor quietly providing a little boost on hills.