Umair Gaines
Electric vehicle conversion is the process of replacing a car's combustion engine and connected components with an electric motor and batteries. This allows you to keep your vintage car while enjoying the benefits of an electric vehicle. The process involves careful consideration of the space available for batteries and motors, as well as the ability of the original chassis to support the added weight. The cost of conversion depends on various factors, including the complexity of the vehicle, performance requirements, and the range and type of batteries used. While it is possible to convert almost any vehicle to electric, some cars are better suited for the conversion than others.
| Characteristics | Values |
|---|---|
| Vehicles suitable for conversion | Almost any vehicle can be converted to electric, but some are better suited than others. Older cars are less complex and easier to convert. Lighter vehicles are preferred as they maximise distance travelled per battery charge. |
| Conversion process | The internal combustion engine, transmission, fuel tank, exhaust system, starter, and radiator are removed and replaced with an electric motor, controller, and battery pack. |
| Conversion kits | Conversion kits are available and include the components needed for conversion. Custom kits are tailored to specific vehicle models, while universal kits can be installed in a variety of vehicles. |
| Cost | The cost of conversion depends on factors such as complexity, performance, range, charge time, and custom components. Conversion costs can range from £6,000 to over £500,000. |
| Time | The time required for conversion depends on the level of complexity and can vary from four to six weeks. |
| Benefits | Electric vehicles are more environmentally friendly, have lower long-term costs, require less maintenance, and have better performance and acceleration. |
| Registration | Converted vehicles may need to be re-registered. |
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What You'll Learn
Electric vehicle conversion kits
One of the leading companies in this space is EV West, known for its exceptional selection of parts and high-quality kits. They cater to a wide range of vehicles, from muscle cars to microbuses. Another prominent name is Hypercraft, offering 18 premium, easy-to-install EV platforms that are both modular and scalable, making them adaptable to any vehicle type and size. Their platforms include physical components like motors, batteries, and wiring, as well a software solution for seamless integration.
For those seeking a more affordable option, NetGain Motors offers a range of products for different budgets. They are the exclusive global distributor of elite brushed DC motors, including the HyPer, WarP, ImPulse, and TransWarP motors. Their economy kit, available through DIYev, delivers impressive performance with a 120 peak horsepower and 162ft/lb peak torque.
Additionally, Chevrolet has introduced its eCrate system, a comprehensive kit with all the primary elements needed for a conversion. This system is specifically designed for vehicles with a conventional driveline and offers increased torque in lower gears and extra speed with overdrive. It includes a 66 kWh lithium-ion battery pack and a 400-volt electric drive motor.
Lastly, it's worth noting that while converting an old car to electric can be an exciting project, it may not be a cheap endeavour. The cost of a conversion kit can be comparable to the price of a new car, and additional expenses, such as batteries and charging systems, should be considered.
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Choosing the right battery
Firstly, it is important to consider the amount of power you want for the EV. The peak power output of the motor and the peak current the motor will use are factors that will determine the maximum discharge output of the battery pack. The continuous power used by the motor while the EV is in use will also determine the continuous discharge current of the batteries.
The intended speed and range of the vehicle are important factors. The battery pack must be able to deliver the desired performance and range. The range you want for your EV determines the final size of the battery pack. You need to decide on the theoretical range you will need and convert this to kWh capacity.
The space available for the battery pack is also a critical factor. The design of the box that will house the battery pack can be quite a puzzle. When the required power is known, you can choose the battery or module you will use. The voltage will determine the total capacity and power of your battery pack. If you have already chosen the other drivetrain components, such as the motor and controller, then you will know the voltage you will need. Each battery connected in series will add up to the total voltage.
Finally, it is worth noting that batteries come in various chemistries, each with unique properties and applications. For small electric vehicles, it is desirable to have a battery with a low weight, compact size, plenty of current delivery for quick acceleration, and high capacity for long-range.
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Conversion costs
The cost of converting a vehicle to electric power depends on several factors, including the type of vehicle, the chosen conversion kit, and the proficiency of the mechanics. The price can range from $5,500 to $25,000, with some conversions even costing $40,000 for trucks.
The most significant cost factor is typically the battery pack. Lithium-ion batteries are commonly used, and their cost can be high, especially if a high-capacity pack is required for extended range. The cost of batteries and installation can be expected to be around $1,000 to $3,000.
The choice of conversion kit also plays a substantial role in the overall cost. Premium kits offer advanced features and higher-quality components, while budget kits provide basic functionality at a lower price. Custom kits are tailored to specific vehicle models, and universal kits can be installed in a variety of vehicles.
The complexity of the conversion process can vary based on the make and model of the vehicle. Some cars are more straightforward to convert than others. For example, a light car (around 2,000 to 3,000 pounds curb weight) with a manual transmission is ideal. Heavier vehicles can restrict the range of the electric engine, and automatic transmissions use up more power due to constant idling.
The duration of the conversion process can range from a few weeks to several months, depending on the vehicle type, chosen conversion kit, and the proficiency of the mechanics.
While converting a vehicle to electric power can be expensive, it can be a more cost-effective option in the long run. Electric vehicles have lower fuel and maintenance costs, and customers can save money after making the switch.
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Electric car maintenance
Electric vehicles generally require less maintenance than traditional cars with internal combustion engines. However, they are still complex machines that require regular maintenance and servicing.
The battery, motor, and associated electronics require little to no regular maintenance. There are also fewer fluids, such as engine oil, that require regular top-ups or changes. Additionally, electric vehicles have far fewer moving parts, reducing the need for frequent maintenance. The National Renewable Energy Laboratory of the United States predicts that today's EV batteries will have service lives between 12 and 15 years if used in moderate climates. This estimate drops to between 8 and 12 years if the vehicle is regularly used in extreme environments.
Some maintenance tasks that electric car owners should be prepared to perform include rotating tires, replacing various fluids, and changing cabin air filters. It is also important to keep an eye on the brake pads, although these tend to last longer in electric vehicles due to regenerative braking. This feature allows the motor to slow the vehicle by recovering its kinetic energy and feeding it back into the battery pack, reducing the reliance on mechanical brakes.
Other maintenance tasks that may be required include lubricating the brake calipers, especially in areas that use salt to melt snow and ice, and replacing the 12V battery. Some electric vehicles may also need to have their coolant flushed and changed periodically, although this depends on the specific model. For example, Teslas do not require a coolant flush for their entire lifetime.
It is worth noting that electric vehicles have high-voltage electrical systems, typically ranging from 400 to 1,000 volts. Their battery packs are encased in sealed shells and are designed with safety features that can deactivate or isolate the electrical system in the event of a collision. First responders should refer to manufacturer guides and training resources when responding to incidents or fires involving electric vehicles.
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Electric car registration
Electric car conversions are a growing trend, allowing owners to keep their vintage cars while enjoying the benefits of an electric vehicle. The process involves removing the entire internal combustion engine, transmission, gas tank, and exhaust system, and replacing them with an electric motor, controller, and battery. While it is a complex process, it is a manageable one, and a great way to give an older car a new lease of life.
Registering a converted electric car depends on the location and the regulations in place. In the UK, for example, the DVLA will issue a 'Q' prefix registration number if the vehicle does not meet the conditions for an original or age-related registration number. The vehicle must pass a type approval test to receive a 'Q' registration number.
To register a kit-converted vehicle, the following documents are required:
- Form V627/1 - 'Built-up vehicle inspection report'
- The vehicle log book (V5C) for the original vehicle
- Evidence of type approval, if necessary
It is also possible to apply to keep the original registration number if two original major parts have been used along with the original unmodified body.
In the US, registration requirements vary by state. For example, in Arkansas, the conversion must be reported to the Director of the Department of Finance and Administration within 10 days, while in California, pre-1975 makes may be registered as an ICE (internal combustion engine).
It is important to note that regulations may change, so it is recommended to check with local authorities before beginning a conversion project to ensure the vehicle can be properly registered and compliant with all relevant standards.
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Frequently asked questions
The process involves removing the internal combustion engine, transmission, fuel tank, exhaust system, starter, and radiator. These parts are then replaced with an electric motor, controller, battery pack, and other components.
The cost varies depending on factors such as the complexity of the vehicle, the performance required, and the range and charge time desired. A basic conversion can start at around £6,000 ($8,300), while a more expensive retrofit can cost $20,000 or more.
The time required depends on the level of complexity of the conversion. On average, conversions take between four and six weeks, but waiting lists can be long.
Electric vehicles are more environmentally friendly, last longer, and can save money in the long run due to lower fuel and maintenance costs. Converting an existing vehicle to electric is also often more cost-effective than purchasing a new electric vehicle.
Older, simpler vehicles are generally better suited for conversion, as they have fewer components and are less complex. Lighter vehicles with manual transmissions are also preferable, as heavier vehicles can restrict the range of the electric engine.
