Electrifying the Baja: How a 2006 Jeep Grand Cherokee is Transforming Off-Road Racing

A 2006 Jeep Grand Cherokee All-Electric Trophy Truck

n rugged Denver, Colorado, where off-road enthusiasts live for the thrill of dust and dirt, Robert Schmidt, an electrical engineer is turning a 2006 Jeep Grand Cherokee into an all-electric trophy truck. His audacious dream is built for the Baja 1000, one of the most punishing off-road races in the world. The goal? To prove that electric vehicles aren’t just for city streets; they can dominate the off-road scene too. The seeds of this project were planted years ago at Red Rocks Community College, where Robert first dipped his toes into the world of off-roading. His first project, affectionately known as the Big Red Jeep Project, was a rock-crawling beast that quickly became the talk of the campus, and the off-road industry. The project landed 18 sponsorships and raised around $50,000 in parts, labor, and donations. But as successful as that build was, Robert wasn’t satisfied. He wanted more—a lot more!

“After the Big Red Jeep Project, I knew I wanted to take things to the next level,” Robert recalls. “I’ve always been passionate about off-roading, but I’m also an electrical engineer, so the idea of blending those two worlds was irresistible. That’s when the idea of building an electric trophy truck for the Baja 1000 hit me. It was ambitious, sure, but that’s what made it exciting.” With the dream firmly in place, Robert took his vision to the Colorado School of Mines, where he pitched the idea as a Capstone design project. This was the first student-led initiative of its kind, and it quickly gained momentum. With a team of 14 fellow engineering students, nearly $90,000 donated from their network, and 25 sponsorships from industry giants like RideHard America, Fox Factory, Revolt Systems, Baja Designs, Smith Power, and Altitude Steel, the project was off to a roaring start. The project became well-known in the Colorado School of Mines town of Golden. These students would go on to speak at events for their sponsors such as the Buffalo Rose gathering in 2022 and SOC 23 where they were some of the main speakers talking about their project.

Building a Beast

Choosing the 2006 Jeep Grand Cherokee as the base was no accident. Unlike traditional trophy trucks, which are typically built from large, heavy-duty frames, the Grand Cherokee offered a more compact and lightweight platform—ideal for an electric conversion where weight is a crucial factor. “We wanted something different,” says Anthony Boyd, the project’s mechanical team captain. “Most trophy trucks are based on big-bodied trucks, but we wanted to stand out. The Grand Cherokee was unique, and by starting with a smaller vehicle, we could shave off some weight right from the beginning.” However, turning a unibody SUV into a 6,500-pound off-road monster wasn’t straightforward. The team had to strip the vehicle down to its bare bones, parting out everything they could to fund the build. The first major challenge? The frame. “At first, we tried to adapt the existing frame rails, but they just couldn’t handle the stresses of a trophy truck,” Anthony explains. “We quickly realized we needed to start from scratch with a custom tube chassis.” Luckily, the team has local support from Altitude Steel who provides them with their metal and has made it possible for this team to build a dream chassis, battery boxes, and any of the designed parts you see.

This realization led the team to scan a precise 3D model of the Jeep in SolidWorks, which allowed them to build the first rolling chassis. Unfortunately, they soon realized the frame rails were a serious weak point and needed to think about other options. ‘‘After some talks, we decided to cut the frame rails out of the vehicle to build a full tube chassis from the ground up. This is the point we are currently at’’. This digital blueprint allowed them to design and test every aspect of the build virtually. The result was a fully custom tube chassis, designed to house a powerful electric drivetrain and support the massive suspension system needed for off-road racing. Only then the full team, composed of Max Billington project advisor, Anthony Boyd,  Adam Schwartz, Blake Partis, Christopher Combs, Curry Gardner, Graham Gates, Zahryn Martinez, Zachary Mckenna, Joe Nagle, Carly Oliver, Titus Reed, and Benjamin Wartofsky could break out their tools and get started. Also, US Engineering sponsored the project donating Talyn Larimer’s time, who’s a professional welder.

One of the most critical components of any trophy truck is its suspension. The team worked closely with Fox Factory to check their design, and now feels they have a system that could handle the immense weight and stresses of off-road racing. The front suspension features 14-inch coilover shocks, and 14-inch bypass shocks with custom valving, while the rear sports 16-inch coilovers, and 18-inch bypass shocks also custom-valved, to provide the necessary wheel travel to be competitive. This is a stark contrast to typical off-road vehicles, which usually have only 6-12 inches of suspension travel. “The suspension is what really sets a trophy truck apart,” Robert explains. “We needed something that could handle the extreme conditions of Baja racing—high speeds, big jumps, and rough terrain. The shocks give us roughly 26 inches of play in the front, and 30 inches of play in the rear, which is crucial for maintaining control and stability.  Now we just need to decide where to limit things with limiting straps and bump stops.”

Hot Swap

The team wanted the most powerful electric drivetrain and opted for a Revolt Systems 450 kW crate motor. Originally designed for high-performance applications, it was specially modified by Revolt Systems to withstand the extreme conditions of the Baja 1000. The motor is rated at 400 volts but will be pushed to 440 volts in this build, delivering between 800 and 1,000 foot-pounds of torque and between 350 and 400 kW (469-536 hp)! “The Revolt Systems motor is an absolute beast,” Robert says with a grin. “We’re talking about serious power here. Revolt Systems even sealed the motor to make it waterproof and dustproof—an essential modification for the harsh conditions of off-road racing.”

Powering this beast of a motor is a custom-designed battery system, featuring three packs, composed of six Tesla P100D 6.3 kWh modules each, all sourced from Stealth EV. These packs weigh in at 500 pounds a pop and are configured in a 1P18S setup, providing a total capacity of 113.4 kWh. You may be thinking that would take a ton of wires, and you would be correct. The team is working with a local sponsor AllCable who provides them with their wire needs. The batteries are strategically placed throughout the vehicle to optimise weight distribution, with one pack in the engine bay and two more behind the driver and passenger seats. To top it off Ashville Micah has provided the group with Micah sheets to line the packs. “One of the unique aspects of our design is the hot-swappable battery packs,” Robert explains. “We’ve designed quick-disconnects for both the coolant and electrical connections, allowing us to swap out depleted batteries in minutes during a race. It’s a game-changer, if it works in real life, competition conditions, that is.”

This innovative approach to battery management is essential for the Baja 1000, a race where every second counts. Of course, the team could not have done this without the support from AEM EV and their management systems for their battery packs, and drivetrain. The team plans to station fully charged batteries at designated points along the race route, allowing them to quickly swap out the packs and get back on the road without the lengthy downtime required for traditional charging. Additional RideHard support vehicles will aid the team in the event of breakdowns and medical emergencies.

Power Steering, Cooling, and More

Building an electric trophy truck isn’t without its challenges, and the team has faced plenty along the way. One of the biggest hurdles was the power steering system. With the vehicle weighing 6,500 pounds and sporting massive 40-inch tires, they needed a power steering solution that could handle the load—something that didn’t exist off the shelf. “We searched for months to find a power steering system that could handle this beast,” Robert recalls. “We finally found a high-voltage system from Radial Dynamics and Terzo, capable of delivering 10 kW of power—five times more than a standard system. It was a huge relief to find something that could power the trophy truck steering rack provided by Howe Performance and their team.”

Another significant challenge was cooling the motor and batteries. With the vehicle expected to endure extreme temperatures and high speeds, the team needed a robust cooling system to keep everything running smoothly. They opted for dual coolant loops, using Tesla pumps to circulate coolant through the motor and batteries, with additional cooling provided by racing car radiators mounted in the side windows.

“We’ve been told that our cooling system might be overkill, but I’d rather have too much cooling than not enough,” Robert says. “The motor will likely get the hottest, but we’ve designed the system to handle it. We’ll find out for sure when we hit the track.”

The Road Ahead

With the mechanical and electrical systems coming together, the team is now focused on finalizing the build and preparing for their first race. The goal is to debut the electric Jeep Grand Cherokee at the 2025 Baja 1000, but they have their sights set on other events as well.

“Realistically, we’re aiming for next year’s Baja 1000,” Robert says. “Before that, we want to take the truck to events like Pikes Peak, the Mint 400, and maybe even SEMA to show off what we’ve built and how we’re pushing the boundaries of what electric vehicles can do.”

The journey from concept to competition has been long and filled with obstacles, but Robert and his team are more determined than ever to see it through. Having built their own shop from the ground up, the team now feels they are ready to make some real strides. Their electric Jeep Grand Cherokee represents the future of off-road racing, where sustainability and performance go hand in hand.

As the team continues to work tirelessly in their Denver shop, they’re not just building another Big Red Jeep—they’re building a legacy that proves EVs have a place in the world of high-performance off-road racing. And as they prepare to take on the Baja 1000, one thing is certain: the electric revolution is coming to the dirt! For those interested in following the build or getting involved, the team is active on Instagram @Electric.Baja.

SPECS

2006 Jeep Grand Cherokee Electric Trophy Truck by The Electric Baja Build

Owner: Robert Schmidt
Location: Denver, CO
Occupation: Electrical Engineer, business owner, entrepreneur

Vehicle:

Year, Make, Model: 2006 Jeep Grand Cherokee
Overall Vehicle Weight: 6,500 lbs
Build Time: Over 1 year
Build Cost: $150,000 – $200,000 (parts, labor, overhead)

Motor & Drivetrain:

Motor Swap Performed by: The Electric Baja Build (Robert & Anthony)
Motor: Revolt Systems 450 kW crate motor, sealed and waterproof for off-road conditions
Power Output: 350-400 kW (469-536 hp)
Torque: 800+ ft-lbs at the yoke
Voltage: 440V
Max RPM: 8,000 at the yoke
Control System and Software: AEM EV (AEMCal, AEMData)

Motor/Transmission Mounts: Custom

Drive Shaft: Pending selection from Tom Woods Custom Driveshafts or Bill’s Englewood Driveshafts
Gears/Ratio: East Coast Gear Supply 5.44 gears
Axles: East Coast Gear Supply Ford 9-inch full float CAA

Battery System & Charger:

Battery Pack Design: Custom, 3 packs of 6 Tesla P100D cells
Battery Capacity: 113.4 kWh
Cell Type: Tesla P100D 6.3 kWh packs (x18)
Configuration: 1P18S
Battery Locations: One in the engine bay, two behind the driver/passenger seats
Charging Rate: 6.6 kW AC charging, with plans for DC fast charging
Cooling System: Dual coolant loops for motor and battery cooling, with Tesla pumps and racing car radiators

Chassis & Suspension:

Chassis: Custom designed from a Jeep Grand Cherokee unibody turned full-frame custom tube chassis
Front Suspension: Fox Factory, 14-inch C/O (R/R) 3.0 Series with custom valving, 14-inch bypass 4.0 Series
Rear Suspension: Fox Factory, 16-inch C/O (R/R) 3.0 Series with custom valving, 18-inch bypass 4.0 Series
Control Arms: Custom
Spindles: Custom
Bump Stops: Fox Factory 3.75-inch” bump stops, 2.5 Series
Track Bar: Custom
Shocks: Fox Factory
Air Management System: ARB dual air compressor

Wheels, Tires, & Brakes:

Wheels: RT81 Rock-8 in 17×9.5
Tires: MAXXIS RZR Mud Tires 40×13.50R17 LT (To be replaced with BFG KR3s for racing)
Front Brakes: Brembo or Wilwood TBD
Rear Brakes: Brembo or Wilwood TBD

Body & Paint:

Body Mods: Full custom roll cage, front clip, custom fenders, and custom steel bumpers
Paint/Wrap: Vehicle will be wrapped with sponsor logos and custom design from Ride Hard America
Color: Currently red
Headlights/Taillights: All vehicle lighting supported by Baja Designs
Glass: None, not allowed in competition

Interior:

Seats: PRP Custom seats
Steering Wheel: PRP steering wheel, quick removable
Gauges: AEM CD-7 display

Sponsors and Special Thanks:

Sponsors: Fox Factory, Smith Power Products, Altitude Steel, Baja Designs, Revolt Systems, Blake Street Liquor, Buffalo Rose, US Engineering, AEM EV, Holley Performance, Howe Performance, Stealth EV, PRP Seats, Raceline Wheels, Camburg Engineering, AllCable, Radial Dynamics, Asheville Mica Company
Smaller Partnerships: Sparco, East Coast Gear Supply
Special Thanks: To all sponsors and donors. The team was able to raise close to $90,000 in funds from their network and countless sponsorships to build this fully electric trophy truck