Umair Gaines
Electric vehicles (EVs) are becoming increasingly popular, and it is now easier than ever to own one. While you can buy a brand-new EV, it is also possible to convert an existing car or build one from scratch. Bob Brant's book, Build Your Own Electric Vehicle, is a great starting point for anyone looking to convert a classic car or build a new one. The third edition, by Seth Leitman, is more up-to-date and covers the latest breakthroughs in EV technology. With the right knowledge and resources, owning an EV is now within everyone's reach.
| Characteristics | Values |
|---|---|
| Author | Seth Leitman and Bob Brant |
| Publisher | Amazon |
| Book Title | Build Your Own Electric Vehicle |
| Book Edition | Third Edition |
| Book Format | Paperback |
| Book Description | A step-by-step guide for converting any classic car into an electric vehicle |
| Book Content | Basics of building an EV, design and engineering, AC propulsion, regenerative braking systems, intelligent controllers, batteries, and charging technologies |
| Book Audience | Environmentalists, engineers, students, hobbyists, and mechanics |
| Book Cost | $0 during the free trial of Amazon Prime |
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What You'll Learn
Converting an existing car to electric
The first step is to source an electric motor. You can buy one new, or you could source a second-hand motor, which will be cheaper but may require some work to get it into good condition. The next step is to remove the internal combustion engine from your car and replace it with the electric motor. This will require creating an adapter plate" to connect the motor to the transmission. A coupler will also need to be designed to connect the electric motor's drive-shaft to the transmission.
There are a variety of battery options available, depending on your needs. If you are only going to use your car for short trips, then you may not need a large battery. However, if you want better acceleration or an extended range, you will need a larger battery. The range of an electric car depends on the size of the battery and how you drive. Batteries will need to be replaced every three to four years.
Converting to electric power is a modular process, so you can add parts, such as additional batteries, or upgrade the motor and charging capability at any time. You will need to re-register your car once it has been converted.
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Sourcing an electric motor
One option is to look for second-hand or used electric motors. You can often find these at junkyards, garages, or through online marketplaces. When buying a used motor, it is important to inspect its condition and ensure it is functional. You may need to clean, repair, or rebuild the motor to get it into working order. As demonstrated by one individual, a rusty and greasy motor bought for $50 was restored with some basic repairs and replacement parts, resulting in a decent electric motor for a total cost of $100.
Another approach is to source the individual components of the electric motor and assemble them yourself. This allows you to customize the motor to your specific requirements and ensure the quality of the parts. However, this option requires a more in-depth understanding of motor design and may be more time-consuming and expensive.
Additionally, when sourcing an electric motor, it is important to understand the different types of motors available and their suitability for your EV. Asynchronous or induction motors, for example, are commonly used in EVs for driving at elevated speeds for long periods. In contrast, synchronous motors, which use permanent magnet rotors, are ideal for urban driving due to their ability to handle regular stopping and starting at low speeds.
Furthermore, you can refer to various resources, such as the book "Build Your Own Electric Vehicle" by Seth Leitman and Bob Brant, to gain a comprehensive understanding of EV design and engineering. This book provides detailed instructions and visuals to guide you through the process of building an EV, including the selection and integration of the electric motor.
In summary, sourcing an electric motor for your EV involves considering your budget, performance requirements, and the level of customization you desire. By exploring second-hand options, understanding motor types, and utilizing available resources, you can make an informed decision about sourcing the right electric motor for your project.
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Connecting the motor to the transmission
Firstly, create an adapter plate to facilitate the connection between the motor and the transmission. This can be done by tracing the outline of the transmission on a piece of tagboard and marking the holes. Take this template, along with the motor end cap, to a machinist who can cut an aluminium plate to the required size and shape, ensuring that the holes are carefully aligned. The centre of the motor drive shaft and the centre of the transmission driven shaft must line up perfectly.
Next, design a coupler to mechanically connect both drive shafts. This coupler transfers the rotary power from the electric motor to the transmission. One option is to use a ""Lovejoy"-style connector, which consists of three fingers and a shaft-hole. Place one connector on each shaft and separate them with a rubber "spider". Alternatively, you can bypass the gearbox entirely if your electric motor produces enough torque. However, this method is usually avoided due to the difficulty in obtaining the correct ratio in a differential.
Before bolting the motor and transmission together, ensure that the coupler design suits your specific application. Consider factors such as the diameter and weight of the coupler, as these can impact the ease of shifting. For example, a small diameter, light coupler can make shifting easier by reducing inertia and providing better balance.
Finally, weld the connection between the motor and the transmission. You can either build your own adapter or have one machined specifically for your setup. This step physically joins the motor and transmission, allowing them to work in unison to power your electric vehicle.
By following these steps, you will successfully connect the motor to the transmission, bringing you one step closer to owning your very own electric vehicle.
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Cost estimates for converting to electric
The cost of converting a car to electric can vary significantly, ranging from $5,500 to $25,000 or more. The final cost depends on various factors, including the vehicle type, the chosen conversion kit, and the proficiency of the mechanics.
The most significant expense is typically the battery pack, especially if a high-capacity pack is required for extended range. Lithium-ion batteries are commonly used and can be expensive. The labour cost is another essential factor, as skilled labour is necessary for a successful conversion, and the time and expertise of professionals will impact the overall price.
Conversion kits are available in premium and budget options, with prices varying accordingly. Premium kits often include advanced features, such as regenerative braking, smartphone integration, and advanced battery technology, resulting in superior performance and extended vehicle lifespan. In contrast, budget kits may offer basic functionality at a lower price point, making electric car conversion more accessible, but potentially compromising on performance, range, and durability.
Some companies, such as Electric Car Converts, offer standardised conversion kits for specific car models, like Land Rovers, starting at £60,000 for a standard-range system and going up to £85,000 for a long-range battery pack. Other companies, like Auto Revival, aim to provide budget-friendly conversion services by standardising their processes and keeping costs low without compromising on quality.
Additionally, some individuals choose to build their own electric vehicles from scratch or convert existing cars by sourcing parts themselves. This DIY approach can significantly reduce costs, as seen in an example where an individual purchased a used electric motor for $50 and refurbished it for an additional $50, resulting in a total cost of $100 for a functional electric motor. However, it requires more time, effort, and expertise than using a professional conversion service.
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Charging technologies
Electric vehicles (EVs) have been gaining popularity, and with that, there is a need to understand the various charging technologies available. Charging an EV is not as simple as just plugging it into a wall socket. There are several factors to consider when choosing a charging technology, such as charging speed, cost, and convenience.
One of the most common charging technologies is the use of AC (alternating current) charging stations. These stations are typically found in public places like parking lots and garages, as well as at homes. AC charging is generally slower than other methods but is widely available and suitable for overnight charging or when the vehicle is parked for an extended period.
DC (direct current) fast charging stations are another option that has gained popularity. These stations use high-powered chargers to rapidly recharge an EV's battery, making them ideal for long-distance travel or when a quick boost in range is needed. However, DC fast charging stations are more expensive to install and operate, and they may not be as readily available as AC charging stations.
Another technology to consider is inductive charging, which uses an electromagnetic field to transfer energy to the vehicle's battery. This method is often used for wireless charging, where the vehicle is parked over a charging pad, and energy is transferred without the need for cables or connectors. Inductive charging is convenient and safe but is typically slower than plug-in charging methods.
Lastly, there is battery swapping, where a discharged battery is replaced with a fully charged one. This technology offers a quick and efficient way to extend the range of an EV, although it requires a specialized infrastructure and standardized battery designs. Battery swapping stations can be found in some locations, offering a convenient alternative to conventional charging methods.
Each of these charging technologies has its own advantages and considerations, and the choice depends on factors such as the vehicle's battery capacity, charging infrastructure availability, and the driver's specific needs.
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Frequently asked questions
There are several ways to own an electric vehicle (EV) easily. You can either buy a pre-built EV or build your own. If you want to build your own, there are many books available that can help you get started, such as "Build Your Own Electric Vehicle" by Seth Leitman and Bob Brant. The book provides a detailed overview of EV design and engineering and covers everything from designing your chassis to EV conversions.
Building your own EV can be a rewarding experience and can save you money compared to buying a pre-built one. It also allows you to customize your vehicle to your specific needs and preferences.
Building an EV requires time, effort, and some technical knowledge. You will need to source parts and components, which can be challenging depending on your location and budget. Additionally, you will need to have basic engineering skills or be willing to learn as you go.
Yes, safety is a critical aspect when building an EV. You must ensure that all electrical connections are secure and properly insulated to prevent short circuits or electrical failures. It is also important to consider the weight and balance of the vehicle, especially when dealing with heavy batteries, to ensure safe handling and maneuverability.
