Introduction
Converting a traditional internal combustion engine (ICE) vehicle into an electric vehicle (EV) can significantly reduce your carbon footprint and gas expenses. However, most conversions can cost upwards of $10,000. This guide will walk you through all the key steps to convert your gas guzzler into an EV on a tight budget.
Choosing the Right Base Vehicle
The first step is selecting the right used gas vehicle to convert. The best candidates are:
-
Smaller and lighter vehicles - Less weight requires a smaller, cheaper electric motor. Aim for under 3,000 lbs.
-
Manual transmission - Bypassing the gas engine leaves the transmission unused. A manual gearbox is simpler and cheaper to adapt.
-
4 cylinders or less - Fewer cylinders mean more room for batteries and components.
-
Readable OBD-II codes - Choose a 1996 or newer vehicle so you can access computer codes.
-
No major issues - Avoid vehicles needing major repairs. Focus on minor wear like brakes or torn seats.
Ideal models include older Honda Civics, Toyota Corollas, and Ford Rangers. Check local classifieds and auctions for bargains. Expect to pay under $5,000 for the right base vehicle.
Sourcing the Electric Motor
The electric motor is the heart of your EV conversion and usually the most expensive component. Aim for an AC induction motor in the 15-25kw range.
Salvaged motors from old electric forklifts, buses, or even some EVs can be sourced cheaply from scrap yards. Expect to pay $300-$1000. These require more custom mounting but are very affordable.
New surplus motors are also available between $800-$1500 online. These bolt up more easily but are less powerful than salvaged motors.
Motor controllers start around $300 for basic units. Opt for higher voltage controllers around 600 amps to maximize motor output.
Finding and Installing Batteries
The battery pack will be the most expensive part of your conversion. Lithium batteries offer the best mix of power and range but are pricey.
Lead acid batteries (similar to car batteries) are cheaper but very heavy. You would need over 20 standard car batteries for a decent EV range.
Lithium phosphate (LiFePO4) batteries balance cost and performance for conversions. You can find salvaged Chevy Volt modules online for under $1000 total. New cells start around $2500.
Aim for >20 kWh capacity for a minimum 50 mile range. Mount the modules securely and wire using EV guidelines for safety. Include fuses, a charging port, and a battery management system.
Adapting the Drivetrain
With the motor and batteries installed, you need to connect them to the existing drivetrain:
-
Motor adapter plate - Use an aluminum plate to mount the motor to the transmission. You may need to fabricate a custom mount.
-
Coupler - Use a coupler sleeve to mate the new motor shaft to the transmission input.
-
Wiring harness - Run thick gauge copper wire from the batteries through the controller to the motor. Use EV connectors.
-
Acceleration - Reuse the existing gas pedal by splicing outputs to the motor controller.
-
Gear selector - Keep the shift lever for switching gears. Lock out reverse gear for safety.
-
Brakes - Brake systems are usually compatible as-is. Flush brake fluid and replace pads if needed.
Final Touches
Finish your conversion by:
- Charging components and wiring
- Installing fuses and safety switches
- Adding instrumentation like a volt meter
- Removing unnecessary gas components
- Sealing off the exhaust and fuel systems
- Registering the vehicle as electric
Carefully test all components before your first drive. Consider starting with smaller batteries and upgrading later to spread costs over time.
Total Costs
Here are typical cost ranges for an affordable DIY conversion:
- Base vehicle: $3,000 - $5,000
- Motor and controller: $1,000 - $2,000
- Batteries: $1,500 - $3,000
- Other components: $500 - $1,000
Total for a basic conversion: Around $6,000 on the low end. High-end upgrades can reach $10k-$12k.
With smart sourcing of used and salvaged parts, you can convert an older gas vehicle into a practical EV for under $10,000. Prioritize critical components like the batteries and motor. Over time, you can upgrade certain parts to improve range and performance. Converting your own EV takes work, but provides great rewards for your wallet and the planet.