Umair Gaines
The Mazda RX-8 is a popular choice for car enthusiasts looking to convert a vehicle to electric power. While it is possible to convert the RX-8 to an electric car, it is a complex process that requires significant engineering knowledge and mechanical skill. The conversion process involves removing the internal combustion engine, fuel tank, exhaust system, and other components, and replacing them with an electric motor, batteries, and associated electronics. One of the biggest challenges is packaging and mounting the batteries due to their size and weight, while also maintaining the balance and handling characteristics that make the RX-8 desirable. Additionally, the electrical systems may need to be rewired, and the transmission may need to be adapted to work with the electric motor. The cost of a high-performance conversion can be significant, ranging from £30,000 to £40,000 or more. Despite the challenges, a successful electric RX-8 conversion can result in a high-performance, reliable, and cost-effective electric vehicle.
| Characteristics | Values |
|---|---|
| Power steering | Hydraulic and electric |
| Electric power steering (EPS) | Available in Mazda RX8 |
| Batteries | 1254 lbs |
| Motors | 600 lbs |
| Cells | 48, each weighing 8 pounds |
| Total weight | ~4000 lbs |
| Voltage | 225 Volts |
| Charger | 15 kW 3-phase |
| Cost | £30-40k |
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What You'll Learn
Power steering: Hydraulic or electric?
Converting a Mazda RX-8 to Electric
The Mazda RX-8 is a popular choice for electric conversion due to its handling, acceleration, and top speed. The process involves removing the engine, transmission, fuel tank, and exhaust, and replacing them with electric motors, batteries, and associated electronics. The challenge lies in packaging and mounting the batteries while maintaining the weight balance and stiffness of the car.
Power Steering: Hydraulic vs. Electric
Power steering is a system that assists the driver in turning the wheels, making modern vehicles easier to control and more comfortable to drive. There are two main types of power steering: hydraulic and electric.
Hydraulic Power Steering
Hydraulic power steering (HPS) has been the traditional choice for decades, with a pump, cylinder, and valves controlling hydraulic fluid to provide steering assistance. It offers a direct connection and "feel" that many drivers appreciate. The pump speed is tied to the engine speed, which can make it challenging to make minor directional adjustments at high speeds without oversteering. HPS has been refined over the years and continues to offer excellent performance at any speed.
Electric Power Steering (EPS)
EPS is a newer technology that has gained popularity in recent years. It uses an electric motor attached to the steering system, along with sensors that communicate with the engine control unit to adjust steering settings based on vehicle speed and other factors. EPS provides consistent performance under different driving conditions and improves fuel efficiency by about 1 mpg. However, some drivers find it lacking in "feel" and poorly tuned compared to HPS.
The choice between hydraulic and electric power steering depends on personal preference and the specific vehicle. Hydraulic power steering offers a more direct connection to the road and is preferred by those seeking a more engaging driving experience. On the other hand, electric power steering is more fuel-efficient, provides consistent performance, and simplifies the design by eliminating the need for a belt-driven hydraulic pump.
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Removing the gas tank
Once the fuel is drained, the next step is to physically remove the gas tank from the car. This may involve disconnecting various hoses and lines connected to the gas tank, such as the fuel lines, vent lines, and any electrical connections. It is important to carefully label or mark these lines during removal to ensure proper reconnection if needed. The gas tank is typically secured to the vehicle with bolts or brackets, so removing these fasteners will be necessary to detach the tank.
When removing the gas tank, it is essential to take appropriate safety measures. Working in a well-ventilated area and wearing protective gear, such as gloves and eye protection, is crucial due to the hazardous nature of gasoline. It is also important to properly dispose of any residual fuel or hazardous materials in an environmentally responsible manner.
After the gas tank is removed, the space it occupied can be utilized for other components. The fuel tank space can be used for battery packs or other electrical equipment, maximizing the efficiency of the electric conversion. It is important to consider weight distribution and balance when redesigning the layout of the vehicle to ensure optimal performance and handling.
Converting a Mazda RX-8 to electric power is a complex process that requires careful planning and execution. Removing the gas tank is a significant step in this process, and it allows for the adaptation of the vehicle's systems to accommodate electric power while also reducing the overall weight of the car.
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Electrical setup and control interface
For the electrical setup, it is essential to consider the power requirements of the vehicle and select appropriate batteries and motors. The batteries are a significant challenge due to their weight and size. They can be placed in various locations, such as the fuel tank space, the rear seat space, or even the engine space if the motor and reduction box fit in the transmission tunnel. However, their placement must consider the overall weight balance of the car, ensuring it aligns with the desired distribution. Additionally, the interface between the motor and the RX8 transmission is critical. The shafts must be precisely aligned during rotation, and the spacing must be perfect to ensure full clutch engagement and disengagement.
The electrical setup also includes other components such as the DC/DC converter. While there are affordable options available, they may not meet the desired power and voltage requirements. It is worth investing in a suitable converter that aligns with your specific needs.
The control interface takes on a crucial role in managing the various signals that are typically handled by the RX8 systems. For example, the ignition signal is one such signal that requires a custom control interface during the conversion process.
Additionally, the power steering system is another aspect to consider. The RX8 has electric power steering (EPS), simplifying the conversion process by eliminating the need for a complicated hydraulic system driven by an engine belt.
Converting a Mazda RX-8 to electric power is a complex process that requires careful planning and execution. The electrical setup and control interface are fundamental aspects that impact the vehicle's performance, weight distribution, and overall functionality. It is essential to thoroughly research and understand these systems before embarking on the conversion project.
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Weight balance and battery placement
The Mazda RX8 is renowned for its 50/50 weight distribution, which contributes to its agile handling and responsive driving dynamics. When converting to electric power, it is essential to consider the placement of the batteries to maintain this balanced weight distribution as much as possible. Placing the batteries too high or too far forward can disrupt the balance and negatively affect the car's handling characteristics.
One approach to battery placement is to utilise the space previously occupied by the exhaust and fuel tank. By removing these components and installing a custom-shaped small-cell battery pack, the weight distribution can be better managed. Additionally, the space near the muffler, which is located at the rear of the vehicle, can be reclaimed for the trunk, further optimising weight balance.
Another consideration is the use of a flat piece of steel or aluminium to increase the stiffness of the chassis. This can provide a sturdy platform to mount the battery pack, ensuring a secure and balanced installation. It is also worth noting that the electric motor itself will take up a significant amount of space where the engine previously was, leaving limited room for batteries under the hood. This space constraint further emphasises the importance of strategic battery placement to maintain the desired weight balance.
Converting a Mazda RX8 to electric power presents unique challenges due to the vehicle's original weight distribution and handling characteristics. By carefully considering battery placement and weight balance, it is possible to optimise the electric conversion while preserving the soul of the RX8 driving experience.
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$540.5
Cost of conversion
The cost of converting a Mazda RX-8 to electric power can vary depending on the desired level of performance and the approach taken. For a high-performance conversion, estimates range from £30,000 to £40,000 ($40,000 to $54,000) or more, excluding the cost of the donor car and any necessary body work. This range reflects the potential for costs to increase if specific parts are chosen or customisations are made.
The cost of the donor car, which is the vehicle that provides the parts for the conversion, can vary depending on its condition and specifications. Some people choose to purchase a non-running RX-8 specifically for the conversion project, while others may already own the car and factor in the cost of their initial purchase differently.
The cost of batteries and motors can be significant. A high-capacity battery pack, such as a reconditioned Tesla S 85kWh pack, can cost around $12,000. Motors can also be expensive, with a Tesla Model 3 drive unit rated at 220 kW potentially costing around $8,000.
In addition to the cost of parts, there may be shipping costs and engineering fees to consider. Shipping costs can vary depending on the location of the supplier and the weight of the parts being shipped. Engineering fees will depend on the complexity of the conversion and the rates charged by the engineer or workshop undertaking the work.
It is worth noting that some people choose to undertake the conversion as a DIY project to keep costs down. This approach may be more time-intensive but can result in a significant cost saving. Additionally, some people may choose to salvage parts from their original RX-8 or other sources to reduce costs further.
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Frequently asked questions
A high-performance conversion costs £30-40k, on top of the donor car and any costs to make the donor body structurally sound.
You'll get to keep the handling, with ridiculous acceleration and top speed, as well as reliability and long-run cost-effectiveness.
You'll lose the sound, the transmission, and the feeling of those revolutions. You'll also lose the boot, and the back seats may need to be removed to make space for the batteries.
