Skip to content 
Harbinger Motors unveiled its cutting-edge modular EV chassis solutions at the 2025 ACT Expo, demonstrating how flexible design and in-house manufacturing can reshape commercial electric vehicle (EV) platforms. With engineering leads Lydia Hewitt and Cody Rebergen walking through the latest updates, Harbinger displayed a powerful vision for scalable, serviceable, and efficient chassis systems. Put simply, they’re designing platforms that are ready for diverse applications—from step vans and RVs to fleet delivery trucks.
Designed for Versatility: Applications from Step Vans to RVs
At the heart of Harbinger’s showcase were two key configurations: a full EV rolling chassis and a newly announced hybrid series chassis. The EV variant, built for medium-duty commercial use, targets vehicles like step vans, RVs, and cab-over designs. Flexibility is the key feature. Harbinger’s 158-inch wheelbase chassis supports between three and six battery packs. This allows customers to tailor range and performance to specific use cases.
With a mile-per-kilowatt-hour efficiency rating and modular battery architecture, the vehicle achieves up to 175 miles of range using five 800-volt, 35 kWh battery packs. These packs are connected in parallel, so range can be expanded simply by adding more packs, including post-purchase. This customer-friendly approach not only provides range flexibility but reduces downtime and complexity.
Built in the U.S.: Vertical Integration for Batteries and Motors
Harbinger emphasizes American manufacturing and lean design. Both battery packs and the proprietary drive motors are assembled at the company’s Garden Grove, California facility. The battery system uses common 2170 cylindrical cells, balancing cost, serviceability, and global availability. Each battery pack includes high-voltage disconnects, fuses, and contactors, allowing for easy isolation of faulty packs without affecting overall operation—a critical feature for uptime-focused commercial fleets.
The motor drive unit is equally impressive. Delivering 440 horsepower and 1,550 Nm of torque (amplified to over 18,000 Nm at the wheels via a 12:1 gear reduction), the direct oil-cooled motor uses high-performance components like liquid-to-liquid heat exchangers and internal oil jet cooling for efficient thermal management. Like the battery packs, the entire drive unit is made in-house, streamlining quality control and innovation.
Independent Suspension and Steer-by-Wire: Engineering Advantages
Harbinger’s EV chassis departs from the industry-standard solid front axles and leaf springs. Instead, it uses an independent front suspension with double A-arms. As a result, the vehicle delivers a smoother ride and sharper maneuverability. Additionally, with a 55-degree wheel cut, the chassis achieves a turning radius significantly tighter than traditional internal combustion engine (ICE) vehicles—a major plus for urban delivery and service routes.
An exciting feature under development is Harbinger’s steer-by-wire system. While not yet production-ready due to load challenges with medium-duty vehicles, the tech shows promise for future implementation and greater vehicle control flexibility.
Thermal Management: Compact, Intelligent, and Serviceable
Cody Rebergen, Thermal Engineering Manager, walked the Munro team through the vehicle’s split cooling module architecture, designed to preserve front-end space for upfitters. This choice allows greater flexibility for installing varied vehicle bodies without elongating the chassis—ideal for OEM partners building RVs, box trucks, or specialty vehicles.
The thermal system is centralized in a “thermal box” that includes pumps, valves, and refrigerant control hardware. Capable of running in multiple modes, it can cool batteries and drive units independently or in combination, using either ambient air or refrigerant. The box features quick-connect fittings, making it straightforward to replace or service.
Hybrid Innovation: Extending Range and Real-World Usability
The biggest highlight was the debut of Harbinger’s series hybrid chassis. This new platform was specifically developed to meet rising demands for longer-range applications. In fact, it offers an impressive range of up to 500 miles. At the core is a 1.4-liter, four-cylinder gasoline engine that powers a generator, which in turn charges the vehicle’s batteries. Crucially, it never powers the wheels directly, maintaining the simplicity and control of an EV drivetrain.
This hybrid system is especially appealing for long-haul RV use and delivery fleets struggling with limited charging infrastructure. With a 47.5-gallon gas tank and 87-octane compatibility, the generator can quietly maintain battery charge at a campsite or reduce charging frequency at depots—solving real-world problems for early adopters and fleet managers alike.
Power Export and Mobile Charging: Next-Level Utility
A standout innovation is Harbinger’s DC-to-DC converter, designed for mobile charging or fleet service. With this solution, one vehicle can deliver an “EV jump start” to another—charging 10 miles’ worth of battery in about 10 minutes. Whether helping stranded fleet units or supporting remote operations, this feature enhances reliability and reduces range anxiety for commercial operators.
The vehicle’s high-voltage output adds even more functionality. In particular, users can run full RV “house” systems directly from the chassis. This eliminates the need for separate generators or auxiliary battery setups. This integrated architecture streamlines vehicle design while maximizing utility and reducing weight.
Cost, Simplicity, and Serviceability: A Lean Approach
Everything about Harbinger’s design screams lean engineering. The company’s approach spans everything from modular power systems and flexible battery provisioning to accessible thermal components and simplified hybrid architecture. As a result, they prioritize ease of service, real-world durability, and manufacturing scalability. Furthermore, by integrating key components in-house, they gain tighter control over cost and performance. This level of control is essential for commercial adoption in today’s highly competitive market.
Conclusion: Modular Design with Mission-Ready Performance
Harbinger Motors’ showing at ACT Expo 2025 reflects the company’s commitment to scalable, serviceable, and forward-thinking EV platforms. Whether you’re an RV builder, fleet operator, or step van upfitter, Harbinger’s modular EV chassis solutions offer a compelling blend of flexibility, reliability, and innovation.
Their fully electric and hybrid chassis options prove that real-world challenges—range, infrastructure, and serviceability—can be addressed through thoughtful engineering and tight vertical integration. Moreover, with production lines now active in California, Harbinger is scaling rapidly. Combined with features like high-voltage power export, steer-by-wire prototypes, and intelligent thermal systems, the company is clearly carving out a niche in the next generation of commercial EVs.
Team Up With Munro!
Stay ahead of the EV curve by following Munro & Associates for the latest in teardown insights, cost analysis, and lean engineering reviews. And don’t miss future updates on Harbinger’s modular platform as it enters production. For teardown support, design consultation, or partnership inquiries, connect with Munro & Associates today.