Beatrice Lang
Electric vehicle (EV) conversion is a complex process that requires a wide range of skills, including engineering, fabrication, mechanics, and electrical work. However, with the growing popularity of EV conversions, several resources and kits are now available that can make the process more accessible to DIY enthusiasts. One of the simplest ways to convert a vehicle to electric power is to start with a basic model and add an electric motor, battery pack, and power controller. For those seeking an even simpler option, electric bike conversion kits are also available, offering a cheaper and greener mode of transportation. These kits typically involve swapping out the front or rear wheel for one with a hub motor and adding a battery pack, with some kits offering additional features such as regenerative braking and app-based controls.
| Characteristics | Values |
|---|---|
| Required skills | Structural engineering and fabrication, basic mechanics, high-voltage electrical work, and vehicle 12V electrics |
| Parts to remove | Engine, fuel system, radiator, exhaust, and other internal combustion components |
| Parts to add | Electric motor(s), battery pack, power controller/inverter |
| Controller features | Controls power/speed between batteries and motor; higher amperage improves acceleration, higher voltage improves top speed and efficiency |
| Example vehicles | Mercedes 190 w201, Leaf with a dead battery, Bolt, Miev |
| Online courses | "Electric vehicle high voltage safety training" ($299), "How to plan an EV conversion" ($199), or both for $399 |
| Other resources | EV Alliance's free monthly Charged Chat webinars, grassrootsmotorsports.com forum, endless-sphere.com forum, Instructables.com guides, electric bike conversion kits |
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What You'll Learn
Electric bike conversion kits
One of the most popular options is the E-BikeKit™, which includes everything you need for a successful conversion. From the USA hand-built wheel and LCD dashboard to the small parts, this kit stands out for its completeness. E-BikeKit™ also offers instructional videos and tools to help you boost your revenue and stay competitive in the e-bike market.
Another notable company is Extreme Ebikes Ireland, which provides a wide range of ebike conversion kits, batteries, parts, and components. They specialize in downhill mountain biking and build their own batteries in Ireland using high-quality parts and components. Their kits are known for their quality, reliability, and battery range, ensuring a pleasant electric biking experience.
If you're looking for a cost-effective option, eBikeling offers affordable electric bike conversion kits starting at just $339.99 with free shipping. Their kits are designed to make power and sustainability accessible to all, allowing you to join the electric biking revolution without a hefty price tag. With eBikeling, you can choose from different voltage and wattage options to find the perfect kit for your bike and budget.
Whether you choose E-BikeKit™, Extreme Ebikes Ireland, eBikeling, or another reputable brand, electric bike conversion kits offer a fantastic opportunity to upgrade your traditional bicycle. With these kits, you can simplify your commute, reduce your carbon footprint, and experience the thrill and independence of electric biking. So, if you're contemplating joining the electric bike revolution, consider giving these conversion kits a try!
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Choosing the right car for conversion
Personal Preferences and Intended Use
Some individuals may prefer a small light hatchback, while others might opt for a more rugged utility-type vehicle. Consider your daily driving needs and the type of vehicle that aligns with your lifestyle and practical requirements.
Performance Expectations
If you're seeking a low-cost, reliable car that can handle highway speeds and offer a decent range, focus on vehicles known for their fuel efficiency and practicality. For example, a Nissan Leaf with a dead battery is an affordable option that can be converted to electric power. Alternatively, the Mercedes 190 W201, produced between 1982 and 1993, offers a good balance between age, safety features, comfort, and space for batteries.
Budget Constraints
Your budget will play a significant role in choosing the right car for conversion. Some people start with their existing car since it's essentially "free." Others may purchase cars that need work, allowing them to save money on the initial vehicle cost. Consider your budget for both the vehicle and the conversion process, including any necessary skills development or expert guidance.
Vehicle Compatibility
Not all vehicles are equally suited for electric conversion. Look for cars that have sufficient space for batteries and consider the weight distribution. Additionally, assess the complexity of the original engine and electrical system. Converting a car with a simple structure and fewer electronics may be more feasible for a DIY project.
Reversibility and Classic Appeal
If you're converting a classic car, it's advisable to plan the process to be fully reversible. This approach ensures that you can restore the vehicle to its original state if needed while preserving its classic appeal.
Safety Considerations
Working with high-voltage systems can be dangerous. Consider investing in safety training, such as the "electric vehicle high voltage safety training" course, to protect yourself during the conversion process.
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Removing car parts for conversion
When converting a car to electric, several components need to be removed and replaced. The internal combustion engine, fuel system, radiator, transmission, gas tank, pipes and hoses, exhaust system, and anything else related to internal combustion must be taken out.
This process requires careful planning and a good understanding of mechanics and engineering. The weight and placement of the new electric components must be considered, ensuring they fit within the available space while also meeting requirements for emissions and crashworthiness.
In their place, you will need to install one or more electric motors, a battery pack, and a power controller/inverter. The power controller/inverter is a crucial component, acting as the brain of the electric vehicle by taking throttle and brake inputs and converting DC current from the battery pack to AC three-phase power for the motor.
It is important to note that this process is not a simple task and requires a significant amount of knowledge and expertise. Most people opt to hire a company to handle the conversion or purchase a kit that provides guidance and the necessary parts.
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EV conversion courses
There are a few options for those looking for EV conversion courses. The EV Alliance, for example, offers online guides, training courses, and free monthly Zoom webinars called Charged Chat. Their course 'How to Plan an EV Conversion' costs $199, and they offer another course alongside it for $399 when bought together.
The EV Alliance also emphasises the importance of safety when it comes to EV conversions, especially with high voltage systems being involved. They recommend taking their safety course before attempting any conversion.
Another option for a course is the EV West VW Beetle Kit, which is a turn-key kit that includes carefully picked components for a vintage look.
Before starting any EV conversion project, it is important to speak with a registered engineer to ensure the final product is safe and compliant with regulations. This is especially important given the high voltages involved, which can be very dangerous.
There are also a number of online forums where people share their experiences and knowledge about EV conversions, which can be a good source of information for those looking to attempt a conversion.
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EV conversion safety
Electric vehicle (EV) conversion is a complex process that requires a range of skills, such as structural engineering, fabrication, basic mechanics, high-voltage electrical work, and vehicle 12V electrics. As such, it is important to prioritise safety and seek expert guidance when performing an EV conversion.
One of the key safety considerations is high-voltage electrical work. Working with high-voltage systems can be extremely dangerous and can cause serious harm if not handled properly. It is crucial to have the necessary knowledge and training to work with these systems safely. Organisations like New Electric Ireland offer training programmes to educate mechanics and hobbyists on how to safely carry out EV conversions. Additionally, online courses like the "electric vehicle high voltage safety training" can provide valuable knowledge and potentially save lives.
Another safety aspect to consider is the choice of donor vehicle. The vehicle should have adequate room and load capacity for the batteries, ensuring that they are securely mounted and do not compromise the vehicle's handling or safety. In some countries, the curb weight of the donor car must be retained after conversion. It is also important to consider the type of batteries used. Commonly available and affordable options include lead-acid flooded batteries and AGM (absorption glass mat) sealed maintenance-free batteries. More exotic options like Ni-MH and Li-ion batteries are lighter, longer-lasting, and more expensive.
Before a converted vehicle can be used on the road, it must be assessed by a vehicle safety engineer to ensure it meets the required safety standards. The EV conversion industry has worked closely with regulators to establish safety protocols and ensure that converted vehicles are inspected and tested similarly to any other electric vehicle. This helps ensure the safety and reliability of converted EVs.
Additionally, it is important to source parts and components from reputable suppliers. The EV Alliance, for example, is an alliance of conversion specialists that abide by strict compliance standards and can provide components and advice to those undertaking EV conversions. Seeking guidance from experienced professionals can help ensure a safe and successful conversion.
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