Can I convert a gas vehicle to electric?
by Domenick Yoney on Jun 5th 2009 at 4:27PM 
There are all kinds of reasons why one might want to drive an electric vehicle (EV). Perhaps you're concerned about the environmental damage done by oil exploration, recovery, refining, and the eventual burning of carbon-based fuels. Maybe you just hate handing money over to huge companies with seemingly no ethical integrity. Whatever your reason for oil animosity, one way to quench your desire to be free of the stuff is to drive an electrically-powered vehicle. Whether they have two, three or four wheels, EVs are a feasible alternative for most of your transportation needs.One of the main obstacles you might face in making the switch is availability. There simply aren't too many factory-fresh electric vehicles you can buy today. While that is slowly changing, a way to get around this obstacle is to build your own. We have featured conversions of all size and shape previously here at AutoblogGreen and believe that most people, even with little or no experience, can convert a car from a gas burner to one powered by batteries. Hit the jump and we'll tell you how.
Gallery: Electric Duster Conversion
Photo: creative commons by carabou
Getting started
The first step on your conversion journey is deciding on what sort of vehicle you wish to convert. While you should keep in mind factors such as passenger and cargo capacity needed, it is said that the best conveyance to convert is one that you like. After all, this could be a project you'll spend many hours toiling over so it's a good idea to choose something that you will enjoy driving and owning. Small pick up trucks are a popular choice since there is lots of room for batteries and the suspension is often able to deal with the extra weight. A manual transmission is also preferred.
If you need some inspiration, the EV Album has hundreds of conversions with pictures and information about batteries and other components used, as well as performance. It's probably to a good idea to begin with a car that was recently in running condition. If a vehicle sits for too long many parts, like tires and bushings, may have to be replaced. You can get some more inspiration here and here.
Out with the old
Once you have your vehicle in your garage, the fun part begins. It is time for gasser-rectomy, that is, the removal of all parts related to the burning of liquid fuel. The engine must come out, along with the exhaust system, fuel system and cooling system. Where you and your EV to be are going, you won't be needing a radiator, mufflers or gas tank. Instead, you'll need room for your motor, controller, batteries and charger and DC to DC inverter.
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Decisions
The choosing of the donor vehicle is only the first of several significant decisions. You must also decide what kind of batteries to use, whether your motor will be AC or DC and what voltage to run it at. If you want to keep costs low, it's best to keep with the tried and true. That means lead-acid batteries, specifically golf cart batteries and a DC motor. It's also a good idea to keep the voltage relatively low (144 volts for a smaller car is plenty) as the motor controllers that can take advantage of higher voltages are somewhat pricey.
If you do decide to go with lithium batteries, make sure you are well informed about installation and battery management systems (BMS) as some folks have ruined new and expensive packs by making easily-avoided mistakes. The good news for those who want to go the lithium route is that prices are falling and quality is improving. Probably the most popular brand choice for lithium conversions is Thunder-Sky. They can now be found as low as $1.10 per amp hour.
Resources
The best thing about converting nowadays has to be the huge amount of information available on the internet. Sites such as the Electric Vehicle Discussion List (EVDL) and the DIY Electric Car Forums offer a wealth of information and are full are great people willing to answer reasonable questions from newbies. Lots of individuals who have already traveled down the conversion path have websites replete with videos. One of the better ones is Kiwi EV. Of course, there's nothing quite like the old-fashioned method of meeting people in real life and talking to them and last years soaring gas prices really spurred on the creation of many new chapters of the Electric Auto Association. Chances are there are people in your area already driving electric cars who wouldn't mind the opportunity to show off their handi-work.
Speaking of showing off, we'll leave you with the first in a series of videos about DIY electric cars called, "A Convenient Response to an Inconvenient Truth." Although the actual conversion process isn't shown, Marion Rickard has a beautiful electric Porsche 356 Speedster replica that he uses to illustrate and answer almost every conceivable question one might have about electric cars, from the parts and pieces used to how you actually shift an electric. Have fun and good luck.
Reader Comments (Page 1 of 2)
Phil L. 5:21PM (6/05/2009)
I've spent quite a bit of time researching conversion projects, and would love to try one myself.
So I'll mention a glaring item missing from most conversion projects: Features that are considered fundamental safety items in new (and even used) cars rarely make it into conversions. I was well into talking my wife into buying a not-quite complete conversion project - until she realized it didn't - and would never - have airbags or ABS.
Yes, I know: Many conversion use platforms from before the airbags-and-ABS era. But these two useful functions are very common on many readily available donor vehicles in the 10+ year old range. Both features are (usually) fully electrically powered, and so fit right into the EV paradigm.
Many are willing to forgo these two capabilities on sunny-day fun vehicles. But it we expect people to adopt conversion EVs as daily drivers, we need to find a way to bring features like ABS and airbags along during the EV conversion process.
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FitFan 7:06PM (6/05/2009)
I'm not sure what you mean when you say that it won't include ABS or air bags. It will include whatever came with the donor car.
In California, at least, it's not legal to remove air bags from a car if you intend to drive the car on public roads.
ABS is less important. You can give your wife a trip to a driving school for her next birthday so she can handle braking without electronic aids.
jake 7:47PM (6/05/2009)
@FitFan
He's talking about how many conversions are of older cars which don't necessarily have airbags or ABS as standard.
CaramelZappa 8:49PM (6/05/2009)
Electric car conversions can have both airbags and ABS. A vacuum pump is usually used to power the brakes, often from the first generation Toyota MR2. The electrical system of the original car is usually left completely intact, the only thing you really give up is air conditioning, and there are solutions for that as well.
Phil L. 9:03PM (6/05/2009)
FitFan -
Perhaps this is clearer: Having researched a number of conversions - where ABS and airbags were available options on the donor vehicle - I've been surprised at how few implement these features in the final EV vehicle.
Lad 5:25PM (6/05/2009)
Lead Acid batteries are the weak point of these conversions; they are very heavy and typically require a feeding of water once a month and replacement about every two-three years. Until cheaper, more electrically dense, batteries are available, electric conversion remains a hobby.
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naiche 5:47PM (6/05/2009)
it's only looked at as a hobby because it's not being done on a mass-production scale.
the charge density of lead-acid is fine for many people who don't need to drive 100+ miles a day. I know people who have been driving their EV for about 25 years and they are completely happy with lead-acid.
Last time I checked, you had to change the oil in ICE cars every 3 months. Air filter every 10,000 miles. Fuel filter, and tuneup every 30,000. Many belts. Seems much more complicated and costly than adding a little water every month.
EV conversions need to be taken seriously. The technology is available and suits many people's needs.
Lad 8:03PM (6/05/2009)
Not against BEVs OM, I'm for them...Have written articles pushing them as much as possible.
I'm for the guy who converts his car to a Pd EV even if they are not as effecient as Li-Ion, however the fact is the batteries are still too expensive and that's my complaint. When the price drops down from $about 10,000 to about $2,500 per pack, we can all consider conversions.
naiche 5:35PM (6/05/2009)
By converting a car, you are keeping it out of the landfill, thereby reducing waste, and since you are only consuming a few new parts (ie: motor, controller, batteries, etc), the carbon footprint of manufacturing your new EV is probably 1/3 that of even a NEW electric car.
So this is by far the "greenest" way to go for transportation today, not considering human-powered vehicles or plain walking.
It should be noted that 99% of lead-acid battery material can be recycled and usually the companies that sell the batteries also collect your old ones to be recycled. Lithium Ion can be completely recycled from what I understand, however, I'm not sure if the infrastructure is in place as it is a new-ish technology. Maybe someone else can clarify.
Hope this post inspires some conversions. I myself am already planning mine.
"We don't need no stinkin' GM."
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Earl Killian 8:54PM (6/05/2009)
If you're interested in conversions, join the Electric Auto Association (EAA). The newsletter is helpful, and you can drop in at the local chapter meetings for advice.
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Snowdog 7:10PM (6/05/2009)
Nice Video Series. That old guy really seems to know his stuff.
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gorr 8:58PM (6/05/2009)
I said to explore the possibilities of a small gasoline battery generator fitted to these home-made cars. Is it clear now or what ? It look as all the brains in usa, canada, mexico, south-america, africa, europe, asia siberia are all at the neutral position. It take a small battery to make an electrical car , Let's say 300 pounds of battery maximum and then a small electrical generator set of 10-20 h.p running at a greater efficiency then a big ice fitted to an inadapted transmission like a ferrari of a regular honda. These wannabees are just building desperate limp cars without any new ideas and without good results. One thing that they will never admit is that they cannot monitor correctly the state of charge of their batteries while driving, so even if they pretend 80 miles range, then they can lose power anytime before 80 miles depending on outside temperature and many more events.
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RAN 5:58AM (6/06/2009)
My only problem with conversions such as Rickard's is the use of a DC motor. Besides having to keep the transmission with all it's size and weight (which could be used to carry more batteries, or to simply lighten the vehicle), there is no way to use regenerative braking to extend the range and increase the efficiency. Also, as he mentioned in his drive, the electric motor doesn't provide any braking of it's own, so you will go through brake pads/shoes even faster on a conversion such as this than you would in the ICE version. Thus, two of the potential advantages of EVs are unrealized. Plus which, I doubt that Speedster replica had power steering or a/c to contend with... two more things to add complexity and cost to the average EV conversion.
It is still wildly expensive to have a conversion done that includes regen braking, power steering, a/c, good acceleration, and 120-150 miles of range. Even if you bought an old Boxster for $12,000, by the time you were through, you'd have more money in it than a brand new Boxster S costs. You'd have a terrific green ride, but price-wise you're getting up close to Tesla Roadster territory.
As much as I'd love to have such a car, the price is still prohibitive.
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matthijs 7:00AM (6/06/2009)
For tons of information on DIY conversions I would recommend www.diyelectriccar.com
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DasBoese 8:07AM (6/06/2009)
One thing that bugs me about most EV conversions is that a lot of people seem to choose really bad donor cars (excusable if you get it for free of course). The basic issue is shoving an electric drivetrain into a body that wasn't optimized to take advantage of it and getting at least reasonable range and performance out of it, but there are some cars that are reasonably well-suited to the purpose... and some that aren't. Like two-ton SUVs and boxy cars with the aerodynamic characteristics of a garden shed.
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Jack Rickard 1:44PM (6/07/2009)
I was very pleased to see the article featuring our video on the 1957 Porsche. Thank you.
I do agree with the comment of one responder that DC series systems are quite simple. So are 1957 Porsche's. It was our first conversion, and so none of that was quite a misguided accident.
It went well. I drive the car every day. One of the things lost in all the discussion of EV's is how much FUN they are to drive. It is a different experience, and entirely a pleasant one. While I barely fit in the car, I find myself driving it essentially all the time now, and looking for excuses to go.
Our next project, already underway, is to convert a 2009 Mini Cooper Clubman. Yes, it has air conditioning, ABS power assisted braking, variable electronic rack and pinion steering, heated seats, etc. All the modern conveniences of a current technology car.
And yes, after protracted and exasperating discussions with AC Propulsion Systems, we have opted for an MES-DEA AC induction motor and 3 phase controller, with regenerative braking of course, as the drive train. At this point, I actually think the MES-DEA system may be better than the AC Propulsions system selected by BMW for the Mini-E.
Ours is the Clubman version. It will use a drive train you CAN obtain for money. And we are going to video tape every step of the process. We're also doing some interesting additional mods, such as adding very good Brembo brakes to the front, a Quaif differential to the transmission, lightweight flywheel, etc.
The net result or intent IS to specifically do a modern, complex car, with a fully capable AC induction drive system. And to provide the information so all the people who did NOT get selected in the Mini-E lottery, can build their own. We're using AVAILABLE batteries and AVAILABLE drive systems so anyone can do it.
As to the comment about choosing bad donor cars.... first, not everyone can afford to take a brand new car of their dreams and first gut it, then wire it up with a bunch of components and hope it runs. So far by far the majority of do-it-yourself converters, their project is a bit of a learning experiment, done as inexpensively as is practical. I not only find nothing wrong with that, but applaud it. They're recycling run out cars, and giving them new life, while learning and gaining confidence in the technology.
Much after the fashion of our Speedster, you have to walk before you can run.
Hopefully, with our video series detailing in more step by step fashion with the Mini Cooper Clubman, we can provide information so that an individual COULD tackle conversion of a relatively expensive new car with all the modern amenities, and have some confidence that they can pull it off the first time.
Again, our thanks to Domenick Yoney and autobloggreen for the very kind mention.
Jack Rickard
http://evtv.me
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RAN 4:34PM (6/07/2009)
Jack, I think your Speedster conversion was 1st class, as far as it went. I was on the Beck website last night, playing "what if", but in AZ nobody would build a car without a/c at the top of the list (at least I wouldn't :-)
I also thought your video series was both entertaining and informative.
I wish you luck in your Clubman conversion and I can't wait to see what you come up with.
Regards,
Rick
DasBoese 8:22PM (6/09/2009)
I think you misunderstood me a bit there.
Neither did I say that any older car is a bad donor, nor that converting a new car is in any way better.
My point was just that people should consider aerodynamics and weight when shopping for a donor car, aside from things like suitability for conversion, safety etc. There are plenty of inexpensive older cars which satisfy these requirements, and IMO even preferable to new cars which often struggle with excessive weight.
That said, good luck with your conversion! I'm looking forward to seeing the finished product, perhaps even a comparison to the Mini E.
boo 3:26AM (6/09/2009)
I have been doing a bit of research and have decided to build my first electric conversion car EVER in august.
It will be a porsche 914 and use a 3 phase AC induction motor, with lithium ion batteries. I am using the voltporsche kit from electroauto's website, though im still not sure where to buy the batteries. I will be converting it with a friend, and between us we have ZERO experience with electric/auto anything, so we'll see how it goes.
I'm hoping I can convert it (and get pretty good specs) for $35K max. (Hoping for 80mph top speed, 0-60 in under 12 seconds, and 120+ mile range.) Anything after that is gravy, and I'm hoping for a bit more with lithium ions. (I'm willing to spend 14k on the batteries over the next year). I'm basically just tired of no highway capable EVs existing, and I'm not waiting 3 years for all these auto companies to play catchup.
Any opinions or offers of advice would be greatly appreciated. Even if its just to tell me i'm stupid/crazy.
feel free to e-mail me about it at rheaspams at gmail
I will be converting it in August in the SF bay area. We hope to have it completed in 1 month. (I'm told the thing to do is start a blog about it! haha)
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tommytunes 2:55PM (6/15/2009)
We converted a Ford Explorer to all electric. We used a 3 phase ac motor and lead acid batteries. We fiquired out how to keep the electronically shiffted 4 wheel drive transmission. The car has plenty of power, we have had it to 70MPH. She begins to lose power after 35 miles but is terrific for what we use it for, commuting and errands about town. We can charge it up on either 110 or 220 current. We love 220 because it's faster. We know that lithuim batteries are the way to go half the weight and double the distance and when its time to change the batteries they will be to lithuim. I'll tell you though its nice not buying gas. You begain to feel the savings right away. You can see our build on You tube look for Electric SUV . Its in 5 parts but it gives you alot of information
http://www.youtube.com/watch?v=7OXcnHK-BGw