Wiktor Wise
Electric vehicles (EVs) are the future of mobility, but their high cost prevents mainstream adoption. Building an electric car on a budget is possible, and there are several ways to lower production costs. One way is to use cheaper materials and technology, such as alternative battery chemistries like LFP (Lithium-ion) instead of the more expensive NMC (Lithium Nickel Manganese). Another way to save money is to reuse parts or use cheaper materials for certain components, such as the car bumper, which is typically made from expensive reinforced plastic. Additionally, one can convert an existing car into an electric vehicle, which can be a more cost-effective option. Several resources are available, such as instructional videos, books, and web forums, that provide step-by-step guidance on building or converting an electric car.
Characteristics and Values of Building a Cheap Electric Vehicle
| Characteristics | Values |
|---|---|
| Motor | Can be purchased second-hand for $50 or less. Rebuilding is easy and requires only a handful of parts. |
| Controller | Controls the power (speed) between the batteries and the motor. Higher amperage improves acceleration, while higher voltage improves top speed and efficiency. |
| Adapter Plate | Can be made from a chunk of plate aluminum to attach the motor to the transmission. |
| Coupler | Connects the rotary power of the electric motor to the transmission to power the car. A "Lovejoy"-style connector is a simple option. |
| Battery Pack | One of the more expensive components. LFP (Lithium-ion) based chemistry is cheaper than NMC (Lithium Nickel Manganese) but has lower energy density and weighs more. |
| Exterior and Interior | Bumper can be made from cheaper materials like EPP-high impact foam, which is lightweight, impact-resistant, and easy to form into complex shapes. |
| Kits | Available for under $700, which can be strapped onto a frame/axle/tire set. |
| Conversion | Possible to convert a classic car or motorcycle to electric. |
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What You'll Learn
Sourcing a cheap motor
Firstly, consider buying a used motor. You can often find great deals on second-hand motors from people who are selling spare parts from their own projects. For example, you might come across someone who bought a forklift for a different project and is now selling the motor separately. While these motors may require some cleaning, refurbishment, and part replacements, they can be an excellent way to save money.
Another approach is to keep an eye out for deals on new motors. Sometimes, you can find new motors at a discounted price, especially if you're willing to consider smaller or less powerful options. Additionally, consider the type of motor you need. For instance, 48-volt controllers are typically cheaper because they are commonly used in golf carts.
If you're open to converting a specific type of vehicle, such as a classic car or a motorcycle, you can search for projects with similar vehicles on the EV Album. This online resource contains thousands of homemade electric vehicle projects, and you can search by components used, which can give you a good idea of the types of motors available and the associated costs.
Finally, if you're handy with welding and steel tubing, you might consider fabricating your own frame, which could potentially be cheaper than buying a pre-made one.
Remember, building an EV on a budget is a creative process, and there are multiple ways to achieve your goal.
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Using cheaper materials
One of the most expensive components of a battery electric vehicle (BEV) is the battery pack. The cost of a battery pack is driven by the battery cells inside them and the components needed to make it work safely. A cheaper alternative to the commonly used Lithium Nickel Manganese (NMC) chemistry is Lithium-ion (LFP) chemistry. While LFP has a lower energy density, meaning a pack with similar capacity to NMC will weigh more, it is a more affordable option.
Another way to save on material costs is to source second-hand parts. For example, one person bought a motor for $50 from someone's garage. The motor was rusty and greasy but functional, and after some work to clean and repair it, the total cost was $100 for a decent electric motor.
A third way to save costs is to use cheaper materials in the exterior and interior of the car. For example, car bumpers are typically made from reinforced plastic and painted to match the body colour, which can be expensive, especially if replaced. A cheaper alternative is EPP high-impact foam, a material used in the shipping and packaging industry. It is cheap, lightweight, and can withstand large impacts, making it a suitable alternative.
Finally, it is worth noting that converting an existing car to electric may be more cost-effective than building a new electric vehicle. This is because you can use the car's original transmission to connect power from the electric motor to the car's wheels. However, it is important to consider the difficulty of getting a converted car licensed, insured, and registered for legal street use.
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Converting classic cars
One of the most well-known classic cars to convert to electric is the early Volkswagen Camper, synonymous with hippy culture. The standard petrol engine was underpowered, and when loaded up with equipment, the issues are fixed by an electric motor.
Another popular choice is the classic Mini, which is perfect for city driving thanks to its compact size, while EVs are particularly good around town where you’ll see a maximum range between charges.
When converting a classic car, any suitable parts should be kept, such as the transmission, which can be used to connect power from the electric motor to the car's wheels. An "adapter plate" can be made out of aluminium with holes to line up with the transmission and the end of the motor.
The controller is an important part of the electric car conversion, controlling the power (speed) between the batteries and the motor. The higher the voltage of the controller, the better the top speed and efficiency of the car.
While converting a classic car to electric can be a costly endeavour, with some firms fitting kits for £60k plus, it is possible to build your own electric car on a budget. Cheaper materials and technologies can be used, such as switching from NMC (Lithium Nickel Manganese) to LFP (Lithium-ion) based chemistry for the battery pack.
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Attaching the motor
Building an electric vehicle (EV) is a challenging but rewarding task. While it may be a daunting process, it is possible to build one on a budget. One of the most important steps in this process is attaching the motor, which will be the focus of this guide.
Firstly, it is important to source a suitable motor. You can find cheap motors at junkyards or through personal connections, as one person did by purchasing a $50 motor from someone's garage. It is also possible to rebuild and repair motors to improve their condition and performance.
Now, to attach the motor to the transmission, you will need to create an "adapter plate". This is made from a chunk of plate aluminium with holes that line up with the transmission and the end of the motor. Outline the shape of the transmission on a piece of tagboard, then mark the holes. Take this template, along with the motor end cap, to a machinist who can cut the aluminium plate to size with precision.
The centre of the motor drive shaft and the centre of the transmission driven shaft must line up perfectly. Before bolting the motor and transmission together with the adapter plate, you will need to design a coupler to mechanically connect both drive shafts. There are several ways to do this, but a simple method is to use a "Lovejoy"-style connector. These connectors have three fingers and a shaft-hole. Place one connector on each shaft and separate them with a rubber "spider". The machinist can help by cutting off the ears, lathing a step in the Lovejoy coupler, pushing in the clutch spline, and welding it in place.
Finally, don't forget about the controller, which is a crucial component that regulates power (speed) between the batteries and the motor. A higher-amperage controller will improve acceleration, while a higher voltage will enhance top speed and efficiency. It is recommended to buy the highest-voltage controller that fits your budget.
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Choosing the right controller
When choosing a controller, it is also important to consider the type of motor you are using. If you are using a series-wound motor, for example, a Curtis 400-amp peak PWM controller would be a good option, as it is designed for this type of motor and can run on 48-72 volts.
Additionally, keep in mind that the controller's capacity is marked in amp hours, and draining a battery at a higher amperage will reduce the runtime. A higher voltage controller will also use less amps to do the same amount of work, so it is important to balance the voltage and amperage to suit your needs.
While building an electric vehicle on a budget, it is worth considering that the battery pack is typically one of the most expensive components. By choosing a cheaper battery chemistry, such as LFP (Lithium-ion) instead of the more common NMC (Lithium Nickel Manganese), you can save money. However, this may result in a heavier battery pack due to its lower energy density.
Furthermore, look for opportunities to use cheaper materials in the exterior and interior of the vehicle without compromising performance. For example, instead of a traditional reinforced plastic bumper, consider using EPP high-impact foam, which is lightweight, inexpensive, and can withstand large impacts. You can also purchase kits for under $700 to strap onto a frame/axle/tire set and convert a vehicle you already own.
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Frequently asked questions
You can get started by buying a kit for under $700 that you can strap onto a frame/axle/tyre set. You can also refer to the EV Album, which is a listing of thousands of homemade electric vehicles, to get ideas and refer to what others have done.
You can opt for cheaper materials and technologies, such as using Lithium-ion batteries instead of Lithium Nickel Manganese batteries. You can also reuse parts from old vehicles, such as motors and transmissions, and rebuild them to make them work for your vehicle.
It can be challenging to get your vehicle licensed, insured, and registered for legal street use. It can also be difficult to find the right parts and make sure they all work together.
There are many online resources, such as forums, email groups, and social media groups, where people share their experiences and offer advice. You can also refer to books such as "Build Your Own Electric Vehicle" by Seth Leitman, which provides step-by-step instructions on converting an internal combustion engine vehicle to electric or building an EV from scratch.
