Trystan Casey
The Chevrolet El Camino is an automotive cult classic, and there is a growing interest in converting this vintage car into an electric vehicle. The process of electrifying a classic muscle car like the El Camino involves removing the gasoline-powered components and replacing them with electric-powered parts, such as electric motors, controllers, and batteries. This requires careful planning, expertise, and a significant investment of time and money. The result is a unique vehicle that combines old and new technologies, offering both functionality and fun.
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What You'll Learn
Planning and preparation
Phase 1 - Donor Car:
The first step is to acquire the donor car, ideally an El Camino from 1969-1972, and move it to your workspace. Set a budget for this phase, typically around $5000. It's important to inspect the vehicle thoroughly and address any issues that may impact the conversion process, such as rust, brakes, and suspension. Fix everything that needs to be repaired or upgraded before removing the internal combustion engine (ICE) components. If you're comfortable, you can do these repairs yourself, or you can take the car to a shop for professional assistance.
Phase 2 - Preparation:
This phase involves preparing the El Camino for conversion. Set a budget of around $1000 for this stage. Remove the ICE components, including the engine, radiator, and other unnecessary equipment. Modify the drivetrain, body, and bed to accommodate the electric conversion. You may also want to replace the seats with racing seats, repair any body damage, and upgrade the front clip with fiberglass components for weight reduction and improved aesthetics. Ensure you have the necessary tools and safety equipment for this phase.
Phase 3 - Motors:
Acquire suitable electric motors for your El Camino. A popular choice is the Impulse 9 with a Turbo 400-splined end, paired with Warp 9 Motors, and connected using an adapter plate. This setup provides a good balance between performance and cost. You can also consider NetGain Hyper9 motors, which deliver higher power and torque. The cost of the motors can vary, so plan for a budget of around $4500 for this phase.
Phase 4 - Power:
This phase involves acquiring the necessary batteries and designing the battery packs to power your electric El Camino. Calculate the required voltage and capacity for your needs, typically around 260V-290V using LiFePo or lithium-ferrite phosphate batteries. Consider the placement of the battery packs throughout the vehicle to balance the weight distribution. Additionally, invest in a suitable charger for your battery packs, such as a JuiceBox charger. This phase can be one of the most expensive, with costs ranging from $8000 to $18,000 or more.
Phase 5 - Controller:
Acquire a suitable controller for your electric El Camino, such as the Zilla Z2K or Soliton 1. The controller manages the power delivery to the motors and can impact the long-term performance and reliability of your vehicle. While the Soliton 1 is a more affordable option, consider your specific requirements and long-term goals when making a decision.
Remember, planning and preparation are critical to a successful conversion. Always stay informed about the latest technologies, safety measures, and best practices in the world of electric vehicle conversions.
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Removing the engine
First, prepare the vehicle by draining the oil and antifreeze and removing all hosing. This includes disconnecting the radiator hoses, heater hoses, and any other hoses connected to the engine. It is important to place a container underneath to catch the drained fluids.
Next, remove the accessories and components attached to the engine. This includes the alternator, power steering pump, air conditioning compressor, and any other peripheral components. Label and organize the parts and bolts removed during this process to facilitate reassembly.
Then, disconnect the engine from the transmission. This step may vary depending on the specific model of El Camino, but it typically involves unbolting the transmission from the engine and carefully separating the two. It is important to support the transmission during this process to avoid damage.
After that, lift the engine using the engine crane. Position the crane securely and attach the lifting chains to the lifting eyes on the engine. Lift the engine slowly and ensure it is balanced and secure. Check that the motor mounts are clear of each other and that the blocks under the transmission are secure.
Finally, remove the engine from the vehicle. Carefully manoeuvre the engine out of the engine bay, paying close attention to any remaining wiring or components that may be attached. Ensure that all connections have been properly disconnected before completely removing the engine.
It is important to work cautiously and methodically throughout the entire process, taking note of any specific requirements or variations that may apply to your particular El Camino model. Always refer to a trusted mechanic or professional for advice if you are unsure about any steps or procedures.
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Choosing the right batteries
Choosing the right battery for an electric vehicle conversion is a critical phase in the transfer process. The battery's power and range are the most important factors to consider when buying an electric car battery. The design of the battery pack is determined by the desired power and range. The amount of space available for a battery pack is also critical.
The battery capacity you require is determined by the charging range you want. For example, a Tesla automobile requires 0.2 kWh per kilometre. So, for a car, increase the number of kilometres you want by 0.2 to get the capacity you want. This will give you a rough idea of your battery pack's specified level.
The voltage determines the total capacity and power of your battery pack. If you have already chosen the other drivetrain components, like the motor and controller, then you know the voltage that you will need. Each battery that is connected in series adds up to the total voltage.
When it comes to battery type, you have several options. Lithium-polymer batteries, for example, are known for their high power density and ability to deliver large amounts of current. They are also much lighter than metal-cased cells, but they are more delicate and prone to swelling, which can lead to safety hazards if not properly protected.
Lead-acid batteries are another option, but they are heavier and less powerful than lithium-ion batteries. They can also be challenging to charge below freezing temperatures.
When choosing a battery for an electric vehicle conversion, it is important to consider factors such as available space, desired power and range, charging range, voltage, and battery type. These factors will help determine the right battery for your specific needs and ensure a successful conversion.
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Wiring and routing
Firstly, it's important to understand the electrical system of the El Camino and identify the circuits you'll be working with. Separate the circuits and tackle them one at a time to avoid confusion. The dome light circuit, for example, is unusual because it always stays hot and uses ground switching.
Wiring Diagram and Sources:
Refer to wiring diagrams and schematics specific to the El Camino model you're working on. These diagrams can be found in owner's manuals or online forums dedicated to El Camino enthusiasts. Pay attention to wire colours and their corresponding functions, as well as the locations of fuses, connectors, and relays.
Front Lighting and Headlights:
The front lighting system includes extra-long leads that can be routed for stock or optional appearances. You'll need to connect headlight, parking, and directional light connectors, as well as provide a switched trigger wire for an electric fan relay, typically recommended with AC. Original-style light sockets, switch body connectors, and terminals will help maintain the vehicle's aesthetic.
Rear Body Wiring:
The rear body harness assembly plugs into the main harness, and longer leads allow for stock or custom routing of wires. This includes backup light wires, stop and tail light wires, side marker wires, and fuel tank sender wires. Ensure you have the correct lamp sockets, terminals, and connections for the license plate and other rear components.
Power and Motor Considerations:
When it comes to power, consider the voltage and capacity of the batteries you'll be using. For example, you might opt for 262V worth of 60AH LiFePo cells, strategically placed throughout the vehicle to balance weight distribution. For motors, you could acquire Impulse 9 and Warp 9 motors, connected with an adapter plate, or explore the option of a single Warp 11 with a soliton controller for higher torque.
Routing High Voltage:
One of the challenges in electric vehicle conversions is routing high voltage in a visually appealing manner. The Vintage Iron team, who worked on the Electric Camino project, successfully routed the high-voltage wiring through the frame rails, ensuring a neat and safe installation.
Remember, safety should always be a top priority when working with electrical systems and high-voltage components. Take your time, plan thoroughly, and consult experts or forums if you have any doubts or encounter specific challenges.
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Testing and refining
Testing and Diagnostics
Before taking your electric El Camino on the road, comprehensive testing and diagnostics are essential. This includes checking the functionality of all electrical systems, such as the motor, controller, batteries, and associated components.
Performance Evaluation
Evaluate the performance of your electric El Camino by conducting test drives. Assess factors such as acceleration, top speed, handling, and braking. Compare these against the performance specifications of the original internal combustion engine (ICE) vehicle to ensure your electric conversion meets or exceeds expectations.
Range Assessment
The range of an electric vehicle is a critical factor. Test the range of your electric El Camino by simulating various driving conditions, including city and highway driving. Assess whether the range meets your intended usage, and if not, consider optimizing the battery configuration or energy management systems.
Refining and Optimization
Based on your testing results, identify areas for refinement and optimization. This could include improving the efficiency of the electric powertrain, enhancing the suspension and handling dynamics, or upgrading the braking system to accommodate the unique characteristics of an electric vehicle.
Safety Checks
Prioritize safety by conducting rigorous safety checks. Ensure that all electrical systems are properly insulated and protected from the elements. Check for any potential hazards, such as exposed wires or loose connections. Comply with relevant safety standards and regulations to ensure your vehicle is roadworthy.
Continuous Improvement
View your electric El Camino as a continuous work in progress. Stay engaged with the EV community, forums, and resources to learn from the experiences of other converters. Stay informed about new technologies, components, and techniques that could enhance your conversion. Regularly assess and upgrade your El Camino to keep it at the forefront of electric vehicle innovation.
Remember, the testing and refining phase is an iterative process that requires patience and persistence. Embrace the challenges and enjoy the journey of transforming your El Camino into a cutting-edge electric vehicle.
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Frequently asked questions
The cost of converting an El Camino to electric depends on the type of batteries used. Lead-acid batteries cost around $4500, while lithium-ion batteries can cost anywhere from $15,000 to $20,000. The total cost of the conversion, including the car and a transmission rebuild, can be as much as $30,000.
The time it takes to convert an El Camino to electric can vary depending on the complexity of the project and the resources available. One conversion project took about 200 hours of work over the course of six weeks. Another project took three years to get the car on the road, with continuous upgrades and modifications made after that.
The type of batteries used for an El Camino electric conversion can vary. LiFeP04 batteries are commonly used in EVs and offer decent size and robustness. Lithium-ion batteries are also an option but are more expensive and have a shorter lifespan.
Converting an El Camino to electric offers several benefits. Electric vehicles are more environmentally friendly, with zero emissions. Electric El Caminos can also be more cost-effective to operate, with lower fuel and maintenance costs compared to traditional gas-powered vehicles. Additionally, electric vehicles provide a unique driving experience with features like smoky burnouts and robust electric motors.
