Molly Ayala
There are several options available for converting a classic Mini to electric. Electrogenic offers a 'drop-in' kit that can be installed by a novice from a garage. The kit includes a 60-hp, 100-lb-ft water-cooled electric motor and a 20-kWh battery, providing a range of 80 miles. Jaunt Motors also offers a conversion system that integrates perfectly into the original vehicle, with no modifications required. Fellten offers another conversion kit designed for 1984-1996 right-hand-drive models, which can also be adapted for earlier Minis. YouTuber Rich Benoit converted a Mini Cooper to electric for less than $3,000, using scavenged parts.
| Characteristics | Values |
|---|---|
| Time | The conversion can be completed in a day |
| Cost | The conversion kit and battery alone could cost more than a brand-new Mini Cooper SE electric car. The basic kit is listed at £8,850 + VAT, excluding labour costs. The full conversion kit is £22,253 + VAT, or £26,703 with 20% VAT. |
| Installation | The kit can be self-installed, or installed by a professional |
| Engine | The original engine is removed and replaced with an electric motor |
| Battery | The battery pack is sold separately and can be purchased from the kit manufacturer or a third party. A 12kWh battery pack is designed for urban use, while a 20kWh battery provides a range of 80 miles. |
| Charger | The kit includes an onboard charger, which can be purchased from the manufacturer or a third party |
| Drivetrain | The kit may not include all the components required for the drivetrain, so additional parts may need to be sourced separately |
| Compatibility | The kit is designed for 1984-1996 right-hand drive models but can be adapted for earlier models |
| Reversibility | The conversion process is completely reversible, as the original engine is stored and can be reinstalled at a later date |
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What You'll Learn
Conversion kits
Several companies offer conversion kits for classic Minis, including Electrogenic, Swindon Powertrain, and Fellten. These kits allow you to convert your classic Mini to electric power, giving it a new lease of life and making it more sustainable.
The basic Electrogenic kit is designed for self-installation by the Mini's owner and comes with 20kWh of batteries mounted above the motor, providing around 80 miles of range. An additional 20kWh extension pack can be mounted in the boot to increase the range to around 150 miles. The kit includes a Type 2 socket that feeds a 6.6kW fast charger and comes with normal, eco, and town driving profiles. Electrogenic also offers trained specialists to fit the kit if needed. The kit retails for £15,000 + VAT and shipping and was scheduled to be available in February 2024.
Swindon Powertrain also offers a conversion kit for the classic Mini, which includes one of their electric motors with a peak output of 160 horsepower, mounted to a Mini front subframe. The kit also includes a CV joint housing, an application-specific differential, and other drivetrain components. However, customers need to add a battery pack, motor controller, DC-DC converter, and onboard charger separately. The basic kit is priced at £8,850 ($11,535), but the additional components can significantly increase the total cost.
Fellten's conversion kit is designed for 1984-1996 right-hand-drive models but can be adapted for earlier Minis with non-hydrolastic suspension (Mk1-Mk3). It comes with a brand-new BMH front subframe, high-quality pre-built battery packs with all required safety systems, and high-voltage wiring. It is designed for businesses or Mini owners who want to work with Fellten-approved installers worldwide.
While these conversion kits offer a unique opportunity to modernise your classic Mini, it's important to note that the cost of the kit and battery alone can exceed the price of a brand-new Mini Cooper SE electric car. Additionally, the conversion process may require proper tools, equipment, and training to ensure a safe and successful installation.
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Installation
The installation process for converting a Mini to electric power can vary depending on the specific kit and vehicle used. However, here is a general overview of the installation process based on various sources:
Removal of the Original Engine and Components:
Firstly, the original A-series engine and associated components, such as the gearbox, driveshafts, and suspension, need to be removed from the Mini. This process can be complex due to the unique design of the Mini's engine and transmission mating. It may require mechanical expertise and specialized tools.
Preparation of the Vehicle:
Before installing the electric conversion kit, it is common to prepare the vehicle by servicing key components such as the brake discs, pads, master cylinder, brake lines, dampers, and bushes. This ensures that the vehicle is in optimal condition before the electric conversion.
The electric motor, which can be sourced from various suppliers like Swindon Powertrain or Electrogenic, is mounted onto a new front subframe. This subframe is designed specifically for the Mini and includes brackets and CV joint housings that connect to the original Mini driveshafts. The subframe assembly is then lowered into the vehicle, requiring careful maneuvering to clear brake lines, driveshafts, and other components.
Electrical Wiring and Components:
The electrical wiring process involves following diagrams and splicing wires. Some kits may provide connectors and pre-made wiring harnesses to simplify this step. The installation of the battery pack, motor controller, DC-DC converter, and onboard charger are crucial aspects of this stage. The battery pack, which can be placed in the boot, provides the high-voltage energy required for the electric motor.
Final Assembly and Testing:
Once the electric motor, subframe, and electrical components are installed, the remaining steps involve reassembling the vehicle. This includes attaching the wheels, adjusting the suspension, and reinstalling the interior components. Finally, the vehicle should undergo thorough testing to ensure proper functionality, performance, and safety. This includes testing the regenerative braking, verifying the operation of the electric motor, and ensuring that all electrical connections are secure and insulated.
It is important to note that the installation process may vary depending on the specific kit chosen and the expertise of the installer. Some kits may offer simplified installation processes, while others may require more complex modifications. It is always recommended to consult with professionals or seek guidance from experienced enthusiasts before attempting any vehicle conversion.
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Cost
The cost of converting your Mini to electric depends on the kit you choose and the company you buy it from. The basic kit, which includes the motor and drivetrain components, typically starts at around £8,850 ($11,535). However, the total cost can be much higher when you include the price of the battery pack, motor controller, and onboard charger. For example, the battery pack can cost around £16,000 ($21,033), the motor controller can be £3,860 ($5,074), and the onboard charger can be £1,950 ($2,563). In total, the cost of converting your Mini to electric can be more than the price of a new Mini Cooper SE.
One company offering a conversion kit is Swindon Powertrain, with their Classic Mini Kit priced at a starting cost of £10,620. The kit includes a 70kg HPD E Powertrain setup mounted to a copycat original Mini front subframe and bespoke inner CV joint housings. The power output is 80kW with a short-term peak of 120kW.
Electrogenic is another company that offers conversion kits for Minis. Their kit includes a 3.3kW onboard AC charger and a 60bhp electric motor with a 20kWh battery pack that provides around 80 miles of range. An extra 20kWh unit can be added in the boot but may require installation by one of Electrogenic's installation partners. The cost of the Electrogenic kit is not mentioned, but the company offers a self-install scheme, indicating that they may be a more affordable option.
It is important to note that the prices mentioned above may not include the cost of a donor car, and the total cost of converting your Mini to electric can vary depending on your location and the specific components chosen. Additionally, some companies may offer discounts or grants to offset the cost of conversion.
Converting a classic Mini to electric can be a costly endeavour, but it allows you to combine the classic style of the original Mini with the sustainability and modern features of an electric vehicle. With the growing popularity of electric cars and the push for zero emissions in some areas, converting your Mini to electric can be a worthwhile investment.
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Battery packs
The conversion kit for a classic Mini's battery pack can be expensive, with some kits costing more than a brand-new Mini Cooper SE electric car. The basic kit, which includes the motor and drivetrain components, is priced at £8,850 ($11,535), while the battery pack itself costs £16,000 ($21,030).
Swindon offers a 12-kilowatt-hour battery pack for the Mini conversion. The battery pack, motor controller, DC-DC converter, and onboard charger are sold separately. The onboard charger is a 3.3 kW AC charger. The high-voltage battery can be charged with an output of up to 6.6 kW, enabling a predicted range of around 100 miles.
There are other battery packs available on the market, such as the HyperPack Energy modular battery system, which can be reserved for $100 per unit. These packs are designed to be structurally stable, reducing the need for additional support frames or enclosures. The uniform size of the packs makes them easy to mount anywhere and distribute weight across the chassis.
Another option is to use second-hand battery packs. End-of-life electric vehicle batteries can be used for energy storage applications, and many studies have concluded that they are technically feasible for second-use applications such as stationary grid and backup power. However, the economic viability of installing second-life batteries is still evolving, as there are costs associated with transportation, storage, sorting, testing, remanufacturing, reassembly, repurposing, integration, certification, and installation.
It is important to note that lithium-ion batteries, which are used in most electric vehicles, can be recycled. The U.S. Department of Energy is supporting the Lithium-Ion Battery Recycling Prize to develop and demonstrate profitable solutions for collecting, sorting, storing, transporting, and recycling spent and discarded lithium-ion batteries. Widespread battery recycling would help keep hazardous materials out of the waste stream.
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Driving experience
The Mini Recharged project offers a unique driving experience, combining the classic Mini's traditional design with cutting-edge technology. The electric conversion provides a sustainable future for these beloved classic cars, allowing them to retain their iconic status while embracing a more environmentally friendly approach.
One of the most notable aspects of driving an electric Mini is the silent drivetrain. Gone are the days of noisy combustion engines; the electric motor provides instant acceleration and a quiet driving experience. This not only enhances the overall comfort of the drive but also makes it easier to navigate through low-emission zones in large cities, which are often inaccessible to traditional combustion engines.
The electric Mini's performance is just as impressive as its sustainability. With its compact size and efficient drivetrain, it swiftly navigates city traffic, making your commute a breeze. The low centre of gravity and wheel placement at each corner provide exceptional handling and razor-sharp steering, allowing you to effortlessly tackle bends and manoeuvre through tight spaces.
The Mini Recharged project also offers a range of customisation options to elevate your driving experience. You can choose from various approved enhancements and upgrades to personalise your Mini to your unique driving style and preferences. Whether you prioritise handling, comfort, or aesthetics, there are endless possibilities to create your dream electric Mini.
Additionally, the electric Mini conversions come with different driving modes, such as normal, eco, and sport, allowing you to tailor your driving experience according to your needs and preferences. The sport mode, for example, intensifies power and sharpens response, providing astonishing grip and effortless control for a more engaging and enjoyable drive.
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Frequently asked questions
There are a few kits available to convert your Mini to electric, each with their own pros and cons. The Fellten kit is comprehensive, but there are only two installers in the USA. The Swindon kit is cheaper and less powerful, but you can take it to any installer. Electrogenic's kit is straightforward and can be fitted by any mechanic.
The conversion process involves removing the original subframe and engine, and installing a new electric motor, battery, and subframe. The entire process can be done at home, but it may take months of work.
Converting your Mini to electric improves the performance and reliability of the vehicle. It also results in emissions-free driving and instantaneous acceleration. Additionally, you get to keep the amazing handling and exact weight distribution of the original Mini.
