Electric Car Conversion Kits

Converting an electric car can be both fun and challenging. If you’ve decided you would like to convert a car yourself there’s a few things you have to decide and keep in mind.

Choosing a car to convert to electric

The first step is choosing the vehicle you want to convert. There are many factors that go into such a decision depending on what your priorities are.

Decide the purpose of your electric car

This will be your first decision and most important. To figure this out ask yourself the following questions:

  1. Why do you want an EV?
  2. Where will you drive it?
  3. Who else will drive it?
  4. How many miles do you require on a daily basis?
  5. How often will you drive the vehicle?
  6. With or without passengers?
  7. Will your employer allow me to charge at work?
  8. How much do I want to spend?
  9. How much time do I have for the conversion?

These are important questions that must be answered. Battery weight represents fuel weight; the more fuel you carry, the greater your range. A vehicle that allows all batteries to be located outside the passenger compartment will make it it easier to restrain the batteries for safety in the case of an accident. A vehicle that allows components to be easily replaced will help when testing, upgrading, or replacing batteries. A small passenger compartment will help with heating requirements in the colder areas, especially during the winter.

Evaluate possible vehicles for conversion

Most vehicles break down into 3 main categories:

Sports Cars

Examples include as the Honda CRX, Pontiac Fiero, Toyota MR2, Porsche 914, Fiat X-19, Nissan Pulsar, MGB or MG Midget. Sports cars have limited space and minimal payload capacity.

Passenger Cars and Vans

Examples include the Ford Escort, VW Rabbit, VW Beetle, Saturn, Honda Civic, Geo Metro, VW Vanagan, and Dodge Caravan. Vans are considered herein as a passenger car because they require the batteries inside the passenger compartment. The payload capacity within this class varies considerably from Geo Metros with a payload of 600 lbs to the VW Vanagan with a payload capacity of almost 2000 lbs.

Trucks

Examples include the Chevrolet S-10, GMC S-15, Ford Ranger, Dodge Ram and Rampage, and VW Rabbit Truck. Trucks have the advantage of locating batteries outside the passenger compartment and typically have a frame which permits a higher payload capacity.

Each of these classes have their own characteristics with respect to aerodynamic drag, curb weight, Gross Vehicle Weight Rating (GVWR), passenger compartment, and available space for batteries. Table 1 lists typical vehicles under each of these classes and their range using various lead acid battery packs (6V and 12V). Range is a function of battery weight because the battery represents the fuel. Typically it takes 15-20 lbs of lead to achieve 1 mile in range. A Rule of Thumb is that 1/3 of the EVs weight should be batteries; the other 2/3 represents dead weight (i.e. frame, suspension, body, motor, etc). If you could decrease this dead weight to 1/2 leaving 1/2 for fuel, you would have superior performance.