If you're like me, you love the idea of driving an electric vehicle but don't want to shell out the cash for a brand new EV. Converting an old gas-powered car into an electric vehicle can be a great way to go electric on a budget. In this comprehensive guide, I'll walk you through everything you need to know to convert your old gas guzzler into an EV yourself.
Choosing the Right Donor Vehicle
The first step is picking the right gas vehicle to convert to electric. Here are some things to keep in mind:
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Older and smaller vehicles are often easiest and most cost-effective to convert. Think 1990s hatchbacks and sedans.
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Choose a car with a manual transmission - this avoids having to integrate the electric motor with an automatic transmission.
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Rear-wheel drive vehicles provide the most flexibility for motor placement.
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Opt for a lightweight car. The lighter the vehicle, the fewer batteries you'll need to power it.
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Avoid all-wheel drive vehicles - these are more complex to convert.
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Look for a car in good mechanical shape with no existing issues. This reduces headaches down the road.
For my conversion project, I chose a 1992 Honda Civic hatchback. The light, rear-wheel drive Civic was the perfect candidate!
Sourcing Electric Car Parts
Once you've selected a vehicle to convert, it's time to source the main EV components:
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Electric motor - I opted for a used 9" DC motor which provides plenty of power. New motors can be very expensive.
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Motor controller - This device sends power from the batteries to the motor. I went with a 500 amp curtis controller.
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Batteries - The most expensive part. I used eight 12V lead-acid batteries for a 96V system. Lithium ion packs are ideal but costly.
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Battery charger - I splurged on a nice programmable Zivan NG3 charger. This maximizes battery life.
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Vacuum pump - For the brakes. I used a pump from a wrecked EV.
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DC-to-DC converter - Steps down voltage for accessories like lights. I bought a used one.
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Wiring, fuses, gauges etc. - Essential but inexpensive components.
All in, I spent around $6,500 on parts by buying mostly used or DIY equipment. Not bad!
EV Conversion Process Step-By-Step
With all your components gathered, it's time for the fun part - the actual vehicle conversion. Here's an overview of the process:
1. Remove the Engine and Fuel System
First, remove the existing internal combustion engine, radiator, exhaust, fuel tank, and other unnecessary equipment. This drastically reduces weight.
2. Install Motor Mounts
Bolt the electric motor and transmission adapter plate into the engine bay. I had to fabricate custom mounts.
3. Install Batteries and Wiring
Run heavy gauge cable from the batteries to the motor controller, and lighter wiring to accessories. Take time to properly fuse and insulate everything.
4. Plumb Vacuum Lines
Hook up the electric vacuum pump to provide vacuum for the brake booster. Essential for braking!
5. Add Charger, DC-DC Converter etc.
Mount the battery charger under the hood, and find spots for the DC-DC converter, gauges and other components.
6. Finish Wiring
Complete final wiring and connections - the devil is in the details here. Double check your work!
7. Test Components
With everything hooked up, test each component before a test drive. Verify connections and troubleshoot issues.
8. Get It Inspected and Registered
Finally, obtain a basic inspection and registration to legally drive your EV conversion!
While condensing the many complex steps into a few paragraphs, you get the idea. With diligent research, sourcing and some mechanical skill, converting a gas car to electric is very achievable.
Key Benefits of a DIY EV Conversion
Once complete, an electric conversion provides some awesome benefits:
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Ultra-cheap "fuel" - Electricity costs a few cents per mile versus $0.10+ for gas.
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Environmentally-friendly - Produces zero emissions.
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Strong performance - Instant torque provides great acceleration.
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Quiet, smooth driving - Electric motors are practically silent.
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Mechanical simplicity - Far fewer parts to break than a gasoline engine.
For a few thousand dollars in parts and some elbow grease, I was able to build a zippy electric hatchback that costs barely anything to run. Who needs a Tesla??
While EV conversions take some upfront effort, I found the project incredibly worthwhile. Not only do I save money, but I'm also reducing my environmental impact. What could be better? Converting your old beater into an electric vehicle is challenging but ultimately very rewarding.